EP0417142A1 - Composition d'analogue d'oeuf entier et procede associe - Google Patents

Composition d'analogue d'oeuf entier et procede associe

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Publication number
EP0417142A1
EP0417142A1 EP89905888A EP89905888A EP0417142A1 EP 0417142 A1 EP0417142 A1 EP 0417142A1 EP 89905888 A EP89905888 A EP 89905888A EP 89905888 A EP89905888 A EP 89905888A EP 0417142 A1 EP0417142 A1 EP 0417142A1
Authority
EP
European Patent Office
Prior art keywords
yolk
egg
membrane
analogue
natural
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP89905888A
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German (de)
English (en)
Other versions
EP0417142A4 (en
Inventor
James P. Cox
Jeanne M. Cox
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Individual
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Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0417142A1 publication Critical patent/EP0417142A1/fr
Publication of EP0417142A4 publication Critical patent/EP0417142A4/en
Withdrawn legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L15/00—Egg products; Preparation or treatment thereof
    • A23L15/35—Egg substitutes
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L15/00—Egg products; Preparation or treatment thereof
    • A23L15/20—Addition of proteins, e.g. hydrolysates, fats, carbohydrates, natural plant hydrocolloids; Addition of animal or vegetable substances containing proteins, fats, or carbohydrates

Definitions

  • the present invention relates generally to edible food products, and, more particularly, to analogues of edible natural fresh whole poultry eggs and methods of manufacturing the same.
  • the present invention relates to edible natural fresh whole poultry egg analogue products which can be used with equal facility and can substantially duplicate the results, both nutritionally and in terms of cooking characteristics and/or organoleptic properties of a natural poultry egg. These characteristics and properties are irrespective of whether the egg analogue of this invention is hard boiled, soft boiled, scrambled, fried either "sunny-side up” or “over easy”, basted, poached, or used as a component ingredient of another food product.
  • the whole poultry egg analogue products provided by this invention comprise a synthetic egg with three basic parts; i.e., a yolk surrounded by a vitelline membrane and a white. This invention also includes egg analogues comprised of a yolk encased in a synthetic membrane.
  • the egg analogue of this invention may be formulated to improve, change or compensate for certain undesirable components or fractions inherently present in natural fresh whole poultry eggs such as triglycerides, high- density lipids or cholesterol.
  • the resulting analogue can be prepared employing the present invention to substantially ' approximate the appearance, consistency, cooking characteristics, taste and similar organoleptic properties of a natural, fresh whole poultry egg product.
  • the product when the yolk analogue (hereinafter referred to as the "yolk”) is man-made, the product can be engineered to be "cholesterol free” or, if desired, its cholesterol content can be established at any desired reduced level. Moreover, the calorie content of the egg can be significantly reduced to contain, for example, one-third or less, of the calories contained within a natural egg.
  • Natural fresh whole poultry eggs are known to be prone to bacterial contamination and have been implicated in many cases of food poisoning. Pasteurization and/or ther ostabilization of natural eggs has simply not been an available solution to the problem since such process treatments of natural whole poultry eggs serve to break down the white of the egg, causing it to become thin and runny, and causing the egg to appear old rather than fresh.
  • the natural fresh whole egg is, in other respects, an ideal foodstuff.
  • the natural fresh whole poultry egg is inexpensive; its protein content is widely used as a standard of protein excellence and is assigned a protein value of 100 as compared to other protein substances which measure less; it is versatile, and, it is easy to prepare.
  • the natural fresh whole poultry egg is a delicious food product which is missed by many consumers who have either had to give it up entirely or limit their intake in an attempt to avoid or minimize health problems thought to be related to its triglyceride, lipid and cholesterol contents.
  • U.S. Patent 3,941,892 discloses a sunny-side up simulated egg product, which may be cholesterol-free, that is frozen in a molded state to simulate a natural egg fried sunny-side up. This product is prepared for consumption by simply removing it from the freezer and heating to prepare a simulated sunny-side up egg product.
  • U.S. Patent 3,640,732 discloses a simulated egg which approximates a boiled, poached or f ed egg.
  • the yolk material is poured into spherical molds (yolk size) to gel.
  • the yolk material gels to simulate a yolk.
  • Lynn, U.S. Patent 3,864,500 discloses an egg yolk substitute prepared by combining a non-elastic protein material, oil and salt, simmering at a low temperature and adding a mild acid during continued heating to bring out its flavor characteristics. Water, vegetables, non-elastic protein material and a thickening agent are added with continued boiling. The composition is emulsified and a milk derivative protein is added to form the yolk substitute. The simulated yolk is used as a baking aid, such as in the preparation of cookies, layer cakes, bread and the like.
  • Burkwall, Jr., U.S. Patent 4,046,922 discloses a simulated egg, which contains egg solids, a water absorbing hydrocolloid, a protein binder, water and sugar or a sugar equivalent.
  • the product is shaped in the form of a rounded disk having an inner yellow colored portion and an outer white-colored portion.
  • U.S. Patent 4,103,040 discloses a low cholesterol egg product wherein a wet egg yolk is combined with edible oil by high energy, high sheer mixing. Cholesterol is extracted from the yolk by the oil. The yolk is then separated from the oil and the cholesterol-free yolk material is incorporated into various egg products.
  • a whole egg analogue which is substantially the same in appearance, taste and preparation characteristics as a whole fresh poultry egg.
  • a further object is to provide a poultry egg analogue which is nutritionally improved over-a natural poultry egg, such as by containing fewer calories, higher vitamin levels and the like.
  • An additional object is to provide a poultry egg analogue which contains reduced quantities of lipid components, such as cholesterol, low or high density lipoproteins and triglycerides when compared to a natural poultry egg.
  • lipid components such as cholesterol, low or high density lipoproteins and triglycerides
  • a further object of the present invention is to provide a poultry egg analogue which is free of blood spots, partially developed embryos and other disagreeable organic matter.
  • Another object of the present invention is to provide a poultry analogue in which the white and yolk are separated by a continuous and integral membrane.
  • Another object of the present invention is to provide a whole poultry egg analogue which may be frozen and which is readily microwavable.
  • Another object of the present invention is to provide a poultry egg analogue which may be rendered bacteriologically safe as compared to natural poultry eggs and other egg products.
  • Another object of the present invention is to provide a poultry egg analogue which may contain dietary fiber or nutritional supplements as previously described.
  • FIG. 1 is a cross-sectional diagram of a conventional natural fresh whole poultry egg, depicting the various structural components
  • FIG. 2 is block-and-line drawing illustrative of various process steps or stages that can be employed in the production of a whole poultry egg analogue embodying features of the present invention, and also illustrating diagramatically the approximate shapes that the yolk/membrane analogues assume during formation;
  • FIG. 3 is one embodiment of a forming apparatus that may be employed in the yolk forming station depicted in FIG. 2 for producing whole yolk/membrane analogues;
  • FIGS. 4A through 4C are cross sectional side elevational views of the exemplary whole yolk/membrane forming apparatus shown in FIG. 3, depicting three (3) sequential stops indicating the formation of yolk/membrane analogues.
  • a poultry egg yolk analogue comprising an edible liquid yolk material contained within an edible, synthesized membrane.
  • the yolk analogue described above may be combined with natural egg white, treated egg white or an edible white analogue to form a whole egg analogue.
  • the invention described herein further comprises methods of forming a whole poultry egg yolk analogue which includes the step of forming a synthetic membrane about a natural or synthetic yolk, preferably such that the membrane contains the yolk in substantially a generally spheroidal shape, like a natural egg.
  • the invention described herein further includes a method of forming a whole egg analogue, wherein the yolk analogue is added to a predetermined quantity of natural egg white or an egg white analogue.
  • a cross-sectional rendering has been set forth depicting the structural components of a natural whole poultry egg, generally indicated at 10, with the liquid components of the natural uncooked egg being contained within an outer eggshell 11.
  • a natural whole uncooked poultry egg is an integral, composite, basically liquid unit comprising three components—viz. , i) a liquid yolk, generally indicated at 12, which, although primarily yellow in color actually consists of alternate yellow and white layers; ii) a relatively thin, strong, liquid impervious membrane 14 surrounding and totally enveloping the liquid yolk material 12; and iii), a plurality of liquid, viscous albumen layers, commonly referred to as the egg white, here generally indicated at 15.
  • the vitelline membrane 14 serves two (2) important functions—viz. , i) it contains liquid yolk material 12 in a slightly oval, generally spheroidal shape; and ii), it serves to physically attach the liquid yolk material 12 to the surrounding liquid white material 15 at the interface therebetween. Absent such a membrane 14 the liquid yolk would simply lose its shape and flatten out, spreading over the liquid white material 15 in much the same manner as when the membrane is inadvertently ruptured. Moreover, absent the membrane's ability to physically attach itself to the liquid white material at the interface therebetween, the yolk would simply slide across the surface of the liquid white when placed into a skillet, with the yolk 12 and white 15 becoming separated and residing on different portions of the skillet surface.
  • membrane analogue
  • synthetic and “synthesized” refer to a membrane which is formed to encapsulate the yolk material, but are not intended to imply that synthetic or artificial ingredients need to be included.
  • a preferred liquid yolk material contains as basic components one or more flavorants, one or more viscosity building agents or thickness, an aqueous liquid and an oil or fat.
  • the flavorant contained within the liquid yolk material may be any useful poultry flavorant which is effective for imparting to the liquid yolk material a poultry flavor. Examples include chicken broth as well as other natural and artificial flavorants.
  • One preferred poultry flavorant is chicken broth, which may ideally have a low sodium content. When chicken broth is included in the formulation, it may also serve as the aqueous component of the yolk formulation.
  • Chicken broth may be present, for instance, in an amount ranging from about 5 to about 95 percent of the yolk formulation, preferably about 50 to about 80 percent, and most preferably about 60 to 65 percent. Unless otherwise specified, all percentages herein are given on a weight basis.
  • Substitutes for chicken broth flavoring include hydrolyzed plant protein having a chicken-like flavor, chicken meat and treated egg white.
  • Other generally non-nutritive flavoring components which are sometimes useful include Artificial Egg Flavor, IPC No. 13531023, Natural Egg Flavor, Spray Dried (I.F.F.); Natural Egg Type Flavor, sample no. 9473 (Fritzsche, Dodge & Olcott); Felton Natural Egg Flavor, Water Soluble, PN No. 499715; Felton Yolk Flavor, PN No. 401620; and Alex Fries Artificial Egg Yolk Flavor, no. 83-233.
  • small portions of an organic acid may be included to enhance the egg taste and flavor.
  • lactic acid and/or citric acid may be included and have a flavor enhancing effect.
  • the quantity of flavorant contained in the yolk formulation will depend on taste desires and largely upon the particular flavorant used.
  • Such non-chicken broth flavorings may be present in any suitable amount, for example, amounts ranging from about 0.001% to about 10.0%, and preferably from about 0.01% to about 5.0% of the yolk formulation.
  • Fats and oils are useful for incorporating into the yolk formulation, and include a wide variety of edible oils and fats useful, for building the desired consistency and for imparting the desired mouth feel to the yolk formulation when it is eaten. These are optional ingredients which preferably will be present in amounts up to about 50 percent of the yolk.
  • Margarine contains a variety of such fats, and is particularly useful in that it presents additional flavorant ingredients, such as 2,3-butanedione.
  • Margarine may be present in the yolk formulation in an amount ranging from, for instance, about 5.0 to about 50.0 percent, and preferably comprises about 15.0 to about 30.0 percent of the yolk formulation.
  • Safflower and corn oil margarines are the preferred margarine types.
  • a no cholesterol or low cholesterol oil may be used to enhance the flavor, texture, mouth feel or use in baking as appropriate.
  • Preferred oils which are useful include partially hydrogenated corn oil, vegetable oil, safflower oil and coconut oil. Highly unsaturated fats or oils having an iodine value of over 100 are preferred.
  • the oil may be present, for example, in an amount ranging from about 8 to about 25, and preferably about 10.0 to about 15.0 percent of the yolk formulation. Vegetable oils are preferred to cholesterol-containing oils, since one of the primary objectives is to produce an egg analogue which has little or no cholesterol.
  • the yolk may contain a dairy fat, such as butter, if the cholesterol content of the whole egg analogue is not critical.
  • the selection of the particular oil or fat or mixture thereof for the yolk formulation, or mixtures thereof, can effect the viscosity of the yolk analogue in its precooked as well as its cooked condition. Hence, more fluid fats and oils may be selected to minimize the viscosity of the yolk material, and more saturated fats and heavy oils may be selected when a higher viscosity yolk material is desired.
  • Water (which may be part of the broth) is also optionally incorporated into the formulation.
  • the preferred form of aqueous material contained in the yolk formulation when chicken broth is not used is deionized water in an amount ranging from about 5 to about 90, and preferably about 50 to 85 percent of the yolk formulation. Water is included to adjust the viscosity and impart the proper texture to the yolk analogue.
  • Proteins may optionally be used in the yolk formulation including globular proteins such as albumen, ovalbumin, cooked meat (which may be blended and dried), glycoproteins, myosins, globins, caseins, zein and the like. Such proteins may be present in amounts, for example, ranging from about 0 to about 90 percent, and when present, preferably comprise about 2 to about 10 percent of the yolk formulation.
  • the protein may be treated with a denaturant if necessary.
  • a suitable denaturant is ammonium hydroxide which may be present in an amount ranging from about 0.01 to about 5.0 percent based on the protein content.
  • natural egg white can be included in the yolk formulation.
  • natural egg white When used in the form of natural egg white, it can, for example, form up to about 90 percent of the yolk formulation.
  • non-albumenous forms of protein may be included in the yolk formulation.
  • examples include meat as well as non-meat proteins, e.g., chicken meat, fish and soy protein.
  • These other non-albumenous protein sources may comprise, for example, up to about 90 percent of the yolk formulation, and when present, preferably comprise about 2.0 to 4.0 percent of the yolk formulation.
  • viscosity control agents may also be included in the yolk formulation.
  • Some of these agents may be in the form of hydrocolloids, and are generally useful for emulsifying the oil/fat and the water components or building the viscosity of the egg yolk material to simulate the texture and viscosity of natural yolk material.
  • Many gums and gum-like substances are also useful for at least partially forming a membrane which encapsulates the yolk material. As such, these compounds may act as film-formers, thickeners, viscosity builders, etc.
  • gums and gum-like substances also act as primary components in the membrane system when desired, and assist in membrane attachment to the egg white material, white-over upon cooking, and impart durability to the yolk.
  • Various combinations of these gums may be used to approach the desired texture and consistency of the yolk formulation and to form the membrane surrounding the yolk material.
  • the preferred gums and gum-like ingredients and in particular, alginates, pectin, locust bean gum, tragacanth and carageenan may be present, for example, in an amount ranging from about 0.2 to about 10.0, and preferably about 2.0 to about 6.0 percent of the yolk formulation.
  • the preferred alginates include alginate salts such as sodium alginate and, in particular, sodium alginate low viscosity (“LV”) and sodium alginate high viscosity (“HV”). These alginates may be present, for example, in amounts ranging from about 0.5 percent to about 5.0 percent of the yolk formulation, and preferably comprise about 0.75 to about 3.0 percent of the yolk formulation.
  • alginate salts such as sodium alginate and, in particular, sodium alginate low viscosity (“LV”) and sodium alginate high viscosity (“HV”).
  • LV sodium alginate low viscosity
  • HV sodium alginate high viscosity
  • These gums may be included singly, in combination with the algin, or in combination with each other in any amount, for example, up to about 3 percent. The total amount of gums present in the yolk formulation would typically not exceed about 10 to 15 percent.
  • Starches and starch-like substances which may act as fillers or thickeners in the yolk formulation include corn starch, modified food starches and the like. These optional additives may thicken on heating to form various degrees of cooked yolk appearance, while imparting " a smooth texture to the yolk material when uncooked. These compounds may be present in an amount ranging from, for example, about 0.5 percent to about 10.0 percent of the yolk formulation.
  • Alternative starch-like ingredients include, for example, rice flour, dextrin, tapioca, potato, sodium carboxy ethylcellulose, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose hydroxypropylmethylcellulose, P.S.-60, P.S.-7, Polysaccharide B-1973, and hydroxypropyl starch acetate, which may be included in various amounts.
  • gelatin and gelatin-like substances optionally included in the yolk formulation are used as viscosity- building agents and yolk gelling agents, and impart a characteristic mouth feel to the yolk analogue upon consumption.
  • Preferred gelatin-like substances include collagen, as well as gelatin, about 50 bloom to about 350 bloom, preferably 300 bloom.
  • Gelatin and gelatin- like substances may be present, for example, in amounts, ranging up to about 15.0 percent, and when included are preferably about 1 percent.
  • Alternatives to gelatin which may optionally be used include agar and gluten. When present, these agents preferably comprise in the range of about 1 percent of the yolk.
  • lecithin which is preferably a non-cholesterolized lecithin.
  • Lecithin is useful as an emulsifying agent.
  • non-cholesterolized lecithin include lecithins derived from plant origin, such as soy lecithin.
  • Lecithin may be present in an amount, for example, ranging up to about 5 percent.
  • a metal ion-releasing salt may be incorporated to facilitate any necessary adjustments of the protein and to control any reaction involving the hydrocolloid.
  • the ions contained in such salt may be useful for setting the various thickeners contained in the yolk formulation.
  • the preferred cation is calcium, but iron and aluminum are also operative.
  • the quantity of cation will effect the extent of gellation which occurs in the yolk prior to and during manufacture and cooking.
  • metal-ion releasing salts are heat-sensitive, and therefore may also be included to give additional firmness to the yolk upon cooking.
  • examples include the calcium salts, such as carbonate, citrate, tartrate, lactate and the like. These optional metal salts may be present, for example, up to about 1 percent.
  • the yolk formulation may further optionally contain a small proportion of a sequestering agent believed to aid in controlling yolk firmness.
  • sequestering agents include citric acid, salts thereof, ethylenediaminetetraacetic acid ("ED ⁇ -V'), polyphosphates, such as sodium hexa etaphosphate, and • certain magnesium salts which may be -present in an amount ranging from, for example, up to about 1.0% of the yolk formulation.
  • a sequestering agent When a sequestering agent is incorporated into the yolk formulation, it may also be advantageous to include a • mild edible acid.
  • the acid is helpful since it at least partially overcomes the sequestering agent as the temperature increases during cooking. This is believed to facilitate the release of metal ion ' s by dissociation of the metal ion-containing salt.
  • One preferred mild acid is lactic acid, preferred because it contributes a poultry flavor to the yolk analogue.
  • the yolk formulation may also include an optional fermentative gas-producing compound, such as a sugar, which generates CO- upon fermentation in the presence of anerobic pathogens, e.g. clostridium.
  • the ingredient may be useful to indicate bacterial contamination if it occurs. When used, it may comprise up to, for example, about 5 percent of the yolk formulation.
  • the yolk formulation may further contain an optional deaerating agent, such as a silicor-e, which is useful for eliminating any foam which is otherwise generated during blending of the components.
  • an optional deaerating agent such as a silicor-e, which is useful for eliminating any foam which is otherwise generated during blending of the components.
  • One or more appropriate coloring agents may be included in the yolk formulation to impart to the yolk a finished orange-yellow appearance.
  • a preferred coloring agent is beta-carotene, but other coloring agents are acceptable, such as anna o, F,D & C Yellow No. 5, and the like.
  • the appropriate ingredients are combined and blended.
  • the yolk material may be immobilized in a yolk-like, spherical shape, such as by molding and/or freezing.
  • the frozen or otherwise immobilized material may then have a membrane forming solution or dispersion coated onto its outer surface.
  • the membrane forming solution or dispersion may contain one or more edible hydrocolloids, such as sodium alginate; a combination of membrane forming agents, such as carboxymethylcellulose and guar gum, or a modified food starch, such as a pre-dextrinized rice flour or a treated protein.
  • the yolk analogue, with a membrane solution on its surface, may then be treated to form the membrane by contact with a reactive composition in the form of a vapor or setting bath.
  • the yolk material can be prepared so that it will harden through as it is heated, or so that it will stay soft when heated, depending on the desired specifications.
  • the yolk analogue will be perceived as firmer when chilled, and may become less firm when heated.
  • the yolk analogue may be perceived as firmer setting than would otherwise be the case.
  • Alginates are optional membrane solution components, particularly useful for forming the membrane. Such alginates may be present in any desired amount effective for forming the membrane, e.g., about 0 to about 10 percent.
  • the preferred alginates are salts, such as sodium.
  • the membrane solution may include at least one proteinaceous material such as albumen, solubilized meat, fish, dairy or vegetable protein, alone, in combination or taken together with one or more reactive hydrocolloids such as sodium alginate, locust bean gum, carrageenan, carboxymethylcellulose and the like.
  • the proteinaceous material and a hydrocolloid where combined are preferably in a solution which can be: i) applied to the surface of a frozen yolk analogue and exposed to a setting solution; ii) coextruded about the surface of an extruded yolk analogue and exposed to a setting solution; or iii) the ingredients included in the liquid yolk material and extruded into a setting bath.
  • the setting bath may be heated to about 120°F to about 200°F, preferably about 135°F to 180°F Alternatively, a plurality of successive baths— one at or about ambient temperature and one at elevated or reduced temperature may be used.
  • Suitable membrane ingredients may be selected from amongst the following categories:
  • Proteins, protein complexes and derivatives thereof such as gluten; elastin; albumen; collagen; gelatin; fish, poultry, or other meat proteins; soy; zein; casein; whey; blood; enzymes such as pepsin, erepsin, rennin and peptides and amino acids such as cysteine, cystine and the like;
  • Polysaccharides including carbohydrates, starches and hydrocolloids, such as sodium alginate, microbial alginate, chitin, chitinose, chitosan or other chitin derivatives, propyleneglycol alginate, pectin, amylopectin, sodium pectinate, low methoxyl pectins, gelatin, methylcellulose, carboxymethylhydroxypropylcellulose, hydroxypropylcellulose, ethylcellulose carboxymethylcellulose, hydroxyethylcellulose , hydroxypropylmethylcellulose, P.S.-60, Polysaccharide B-1973, and the like;
  • Gums such as guar, acacia, hydroxypropyl guar, amylose, carageenan, dextran, larch, okra, tamarind, carboxymethylhydroxypropyl guar, xanthan, ghatti, dextrin, locust bean, tragacanth, curdlan, Gelan, baker's yeast glycan and the like; and
  • Modified food starches including dextrins, waxy corn and short grain rice, pregelatinized flour and the like.
  • sodium alginate reacts or cross-links with calcium or similar setting ions present in a setting bath, whether heated, cooled or otherwise, to form a cross-linked matrix-like membrane surrounding the liquid yolk material.
  • a cross-linked, matrix- like alginate membrane is believed to also serve as a supporting matrix for one or more second membrane forming agents utilizing, for example, one or more proteins, proteinaceous hydrocolloids and/or reactive gums.
  • the alginate membrane When used by itself as the membrane forming agent, the alginate membrane may be relatively weak, and burst or break during cooking.
  • a firmer membrane may be created, which is more resilient when subjected to heat during cooking of the egg analogue.
  • Reactive gums such as locust bean gum
  • Locust bean gum is a low viscosity material when placed in cold water, having a viscosity of approximately 200 centipoise (200 cP) .
  • locust bean gum When heated to approximately 140°F., locust bean gum becomes highly viscous and exhibits a viscosity of on the order of 3,500 cP (i.e., its viscosity increases by more than seventeen times) .
  • Carrageenan another suitable reactive gum, also tends to increase in viscosity when heated and then cooled, but, generally only by a factor of about 2:1.
  • Carrageenan is a desirable reactive hydrocolloid gum because it is particularly reactive with proteins. Consequently, when present on or forming part of the surface of the membrane analogue the membrane tends to draw in and attach to the natural egg white or proteinaceous egg white analogue, causing the latter to thicken to the consistency of a natural fresh egg white, bunch up around the yolk, and fixedly attach itself to the membrane analogue surrounding the yolk.
  • one preferred membrane forming system for use in carrying out the invention includes protein as a component, such as albumen, natural egg white and/or a solubilized meat protein together with at least one reactive gum such as locust bean gum and/or carrageenan, used in conjunction with, for example, sodium alginate.
  • protein as a component such as albumen, natural egg white and/or a solubilized meat protein
  • at least one reactive gum such as locust bean gum and/or carrageenan
  • locust bean gum and/or carrageenan swell and become part of the membrane matrix. This serves to form a thin, but strong, liquid-impervious membrane analogue when used In combination with the alginate, surrounding and encapsulating the liquid yolk analogue.
  • Proteins such as albumen can be used by themselves to form the desired membrane where special circumstances dictate.
  • the protein selected is preferably heat coagulated, treated at a pH (past the protein's isoelectric point) to form a solution and then allowed to cool with removal of the treating agents so that it forms a membrane upon placement into a setting bath.
  • a protein or other strong membrane forming agent is contained in the membrane formulation to provide a membrane that is sufficiently tough to withstand cooking without spontaneous rupture thereof.
  • the preferred membrane forming ingredients are alginates and proteins used in combination with one or more gums and/or one or more polysaccharides.
  • a particularly preferred combination of membrane forming agents comprises albumen, sodium alginate and locust bean gum.
  • the protein containing membrane formulation may also contain optional denaturants particularly when used with membrane forming materials and composites thereof.
  • Examples include primary, secondary and tertiary amines, ammonium hydroxide and selected salts and acids, such as dibasic sodium phosphate hydrochloric acid, lactic acid, pyruvic acid and the like. If the denaturant is ammonium hydroxide, it may be evaporated during membrane setting.
  • An alternative preferred membrane-forming system utilizes non-proteinaceous materials present in an amount effective for forming a membrane.
  • One example is a combination of gums, semi-synthetic cellulose derivatives and an alginate, with or without a sequestering agent, and with or without a cross-linking agent present.
  • a combination of guar gum and sodium alginate provides a membrane-forming aqueous solution at concentrations under about 10 percent.
  • the membrane formulation may also contain optional plasticizers which make the membrane more flexible after exposure to the setting bath, such as glycerol, sorbitol and the like.
  • Antifoaming agents may also be included in the membrane forming compositions to prevent air entrapment.
  • Examples include silicone oil, polyglycols and the like.
  • the membrane forming composition may include optional coloring agents to render the yolk containment membrane a color which simulates that of a natural yolk.
  • Water may be included in the membrane solution for imparting the desired viscosity to the membrane solution and for dissolving the water-soluble components. Depending on the levels of membrane-forming components, water can be present up to as high as about 98 percent of the membrane solution.
  • the setting bath or other treatment provided can be adjusted to the particular membrane forming components selected for use in accordance with the present invention.
  • the setting bath solution is preferably aqueous in nature, and may contain one or more reactive compounds, e.g., calcium, in concentrations effective for setting or forming the membrane either from the membrane forming material to form a coating or from the yolk material itself.
  • the preferred calcium compound is calcium chloride present in an amount ranging from about 0.1% to about 10.0%, e.g., about 0.7% of the bath.
  • the bath may also contain one or more acids. Examples of suitable acids include hydrochloric and lactic acid, present in an amount ranging from about 0.1 to about 10.0%, e.g., about 0.7%.
  • the membrane is formed by reaction of the bath acid and calcium ions with the membrane forming agents on the surface of the yolk material. This may include coagulating any protein available, or effective cross-linking of any polymer or gel forming material included in the membrane formulation.
  • the membrane setting bath may be contained in a tank and continuously recirculated as an aqueous setting bath, maintained at a temperature of approximately 120° F. to 180° F. and at a pH value of 6.2 to 6.5.
  • the bath contains the setting agent or those setting agents required to interact with the membrane forming ingredients.
  • one or more enzymes may be incorporated into the setting bath to form the membrane. Examples of such enzymes include proteolytic enzymes, such as pepsin, erepsin and the like.
  • an enzyme setting bath When an enzyme setting bath is used to form the membrane, it is preferable to follow with a second bath useful for deactivating the enzyme, e.g., a scalding bath, with a relatively short residence time, e.g. about 10 seconds to about 2 minutes.
  • a second bath useful for deactivating the enzyme e.g., a scalding bath
  • a relatively short residence time e.g. about 10 seconds to about 2 minutes.
  • the yolk formulation itself may contain sufficient quantities of membrane forming compounds which react with the bath components to form a membrane at the outer surface of the yolk.
  • Such yolk and membrane analogues can be fabricated by incorporating the membrane forming ingredients in the liquid yolk material and extruding the liquid yolk material as discrete globules into a setting bath. The globules are roughly comparable in volume to -that of natural yolks.
  • the bath contains suitable reactants which interact with the membrane forming ingredients in the liquid yolk to form a membrane at the surface of the yolk material, where that surface is in contact with the setting bath.
  • the liquid yolk material within the formed membrane assumes a generally spheroidal configuration which appears to be substantially the same as a natural egg yolk.
  • the percentages of components used in a single extrusion formulation may be varied slightly from the previously described yolk and membrane formulations.
  • the membrane or film-forming ingredient concentrations are increased in the yolk formulation, to provide an adequate concentration of membrane forming ingredients, to react with the setting bath and form a membrane around the outer surface of the yolk analogue.
  • natural egg albumen is included in the single extrusion formula, it would be preferable to include a slightly higher concentration than in, for example, a comparable dual extrusion formulation.
  • the membrane forming components in the yolk composition.
  • the yolk is then treated to create the membrane on its outer surface rather than coating the yolk with the membrane forming composition in a separate step prior to exposure to the membrane setting bath.
  • a membrane is formed surrounding the liquid yolk material as a resul 1 - of a reaction between the membrane forming ingredients and calcium or another suitable ion or setting agents contained within the bath.
  • the formed yolks and membranes are permitted to reside within the bath for a sufficient length of time—generally from about five to about twenty minutes—to insure that the membrane forming ingredient contained within the yolk forming material forms a thin, strong, liquid-impervious membrane surrounding the liquid yolk material.
  • a preferred time in the setting bath is about 8 to 15 minutes, for example, 10 minutes.
  • the discrete, soft, generally spheroidal formed yolk/membrane analogues may be rinsed to remove excess ions from the surface thereof.
  • the yolk/membrane analogues may preferably be maintained for about ten to about twenty minutes in such a rinse, at any appropriate temperature.
  • the liquid yolk/membrane analogues may be allowed to rest on the bottom of the bath and, therefore, assume a generally ovoid yolk-shaped configuration having a flattened bottom, a shape comparable to that of a natural liquid egg yolk when placed on a flat surface.
  • the partially set liquid yolk/membrane analogues may be conveyed in any suitable manner to a second and even a third bath or rinsing operation as necessary.
  • the temperature of these subsequent baths and rinsing operation may range from tepid to an ice water bath.
  • the yolk including the membrane, may then be placed in and bonded to natural egg white or a synthetic egg white analogue appearing as an integral, --well defined, round, glistening globule of the appropriate yellow to yellow- orange color when uncooked.
  • the white portion may contain natural egg white, treated egg white or any other suitable component which will coagulate upon cooking to simulate natural egg white.
  • Alternatives to natural egg white useful in the egg white portion of the composition include blood and whey albumen as well as any other source of edible albumen, other protein containing components, such as uncooked fish jelly, and other transparent or semitransparent proteinaceous materials. Additionally, several polysaccharides may be used to form an egg white analogue which simulates natural egg white upon cooking.
  • the selection of the components used in the egg white material Is, therefore, based primarily on protein content and expense.
  • the egg white material may be treated with any of the thickening agents, such as the gums and polysaccharides, to impart a characteristic viscosity to the egg white material which approximates that of natural egg white.
  • the outer surface of the membrane should bind relatively firmly to the egg white or egg white analogue during cooking.
  • a binding agent may be added to the membrane formulation to facilitate binding between the yolk and the white. Suitable binding agents include powdered proteins, collagen , gluten and many gums and starch-like derivatives, which may be applied in several layers, dusted or coated thickly onto the outer membrane surface. Divalent or trivalent metal ions such as trivalent iron or aluminum also tend to bond the white to the yolk. Such materials may be included in the containment membrane formulation or added to the containment membrane setting fluid.
  • the membrane and the egg white material are preferably attached.
  • an effective amount of a gum may be added to the egg white material or applied to the outer surface of the membrane.
  • a preferred gum useful in this fashion is locust bean gum.
  • a preferred polysaccharide binding agent useful for enhancing the appearance is hydroxypropy methylcellulose ("HPMC").
  • HPMC hydroxypropy methylcellulose
  • a preferred combination additive to treat natural egg white is a combination of locust bean gum and hydroxyprop lmethyl cellulose HPMC.
  • a solution of gums, metal ions and/or phospholipids, such as acacia, carrageenan, locust bean gum and/or HPMC can be added to the egg white material itself—whether in addition to or in lieu of one or more of such ingredients on the surface of or incorporated in the membrane analogue per se—so as to produce thickening, bunching up of the egg white and attachment to the membrane. It is also possible to include polyvalent salts of aluminum, sodium, iron or copper to enhance attachment of the egg white material to the membrane. Examples include aluminum potassium sulfate, aluminum sulfate, ferrous sulfate, ferric sulfate, copper sulfate and copper gluconate in minor effective amounts.
  • Such additions in amounts ranging from for example, about 0.0002 to about 0.05 percent, improve the fresh appearance of the egg white material.
  • the durability of the egg white material may be improved in the presence of heat, e.g., pasteurization, such that the temperature at which the egg white component coagulate may be increased.
  • the locust bean gum, carageenan and HPMC may be combined in the form of a solution of each, for example, about 0.5 percent, and the solution may be added to natural egg white to form treated egg white.
  • a small amount of lecithin preferably soy lecithin, may also be added to the natural egg white to enhance attachment to the membrane by the egg white.
  • lecithin is added in an amount ranging from about 0.1% to 2.0%.
  • the liquid yolk/membrane analogues may be surface dusted with a material—for example HPMC, locust bean gum, carrageenan and/or mixtures thereof— hich serve to promote and enhance thickening and "bunching up” of the egg white around the yolk of the egg. This results in adhesion between the membrane and the egg white material.
  • a material for example HPMC, locust bean gum, carrageenan and/or mixtures thereof
  • the surface of the membrane may be at least partially freeze-dried and immersed in treated, natural or synthetic white while freeze-dried to provide a bond between the yolk and the white.
  • ammonium hydroxide may be used to enhance bonding of the denatured albumen contained in the white to the albumen of the membrane, when an albumen is included therein.
  • the ammonium hydroxide may be removed to complete the bonding process.
  • the whole egg analogue composition described herein may be prepared by blending the yolk material and forming yolk shapes by hand.
  • the liquid egg yolk analogue material may be chilled, frozen, gelled, or otherwise immobilized into discrete rounded shapes or molded "patties". These immobilized yolks may then be sprayed, painted or otherwise treated with a membrane analogue material on the exposed outer surface of each frozen or immobilized patty to form a coating thereon.
  • the formed and coated yolks may then simply be individually immersed by hand in a setting solution or bath to form the membrane.
  • the setting bath in this method of preparation is typically a solution wherein the liquid membrane coating reacts to form a liquid-impervious, thin, strong membrane enveloping the liquid yolk material.
  • the membrane forming ingredients used in this method are either wholly or partially heat responsive, the setting bath may be heated or the setting bath may comprise a plurality of two baths, some of which may be heated and others which are tepid, hot or cold.
  • proteolytic enzymes and/or acids can be used in the setting bath to set the membrane analogue.
  • heat treatment may include a scalding hot dip to deactivate the enzyme, with a dwell time of about 5 seconds to about 2 minutes.
  • the yolk material thaws and/or liquifies if placed into a heated setting bath. It is believed that hydrostatic forces and surface tension serve to cause the yolk material confined within the formed outer membrane to assume a generally spheroidal shape, such as in a natural egg yolk.
  • This type of system-hand application of a liquid membrane coating to a frozen yolk or yolk analogue, followed by a deposit in a suitable setting bath can be automated to permit mass production of whole yolk analogues.
  • the yolk and its surrounding membrane are then placed into the egg white material (natural, treated or analogue) and the entire composition may be cooked and eaten, used in baking or preserved for later use.
  • a second alternative method of making whole egg analogues is a mechanized co-extrusion system wherein the yolk formulation is coextruded with the membrane forming material.
  • the yolk material is not intermixed with the membrane forming material. Rather, the yolk material is extruded from a circular tube and the membrane material is extruded essentially concurrently in an annular shape surrounding the yolk material.
  • a predetermined quantity of each formulation is co-extruded and then interrupted to form a yolk and its attendant membrane. Such a dual extrusion is typically made directly into the membrane setting bath, to effect a rapid formation of the membrane surrounding the yolk material.
  • the forming apparatus for the dual extrusion system may utilize a "dual extrusion" system (not shown) having a first central extrusion nozzle designed to extrude the liquid yolk material, and a concentric annular co- extrusion nozzle surrounding the central extrusion nozzle for simultaneously extruding a liquid membrane formulation in surrounding relation to the extruded yolk analogue in much the fashion of a sausage casing.
  • the co-extruded liquid materials are extruded into a setting bath and pinched, cut, or otherwise subdivided into discrete, somewhat cylindrical, globules having a volume comparable to that of a natural egg yolk.
  • the cutting or separation of the co- extruded liquid components serves to close the somewhat cylindrical co-extruded membrane analogue at the cylinder ends. Since the extruded materials comprise a generally liquid system, hydrostatic forces and surface tension cause the discrete globules to assume a generally spheroidal configuration typical of a natural egg yolk.
  • a preferred alternative method of manufacture encompasses a mechanical process whereby yolk material containing a relatively high level of membrane-forming ingredients is extruded from a single nozzle directly into membrane setting solution.
  • This single extrusion method utilizes the membrane forming agents present in the yolk material to form the membrane on the outer surface of the yolk.
  • FIG. 2 a block-and-line diagram has been provided depicting such a single extrusion yolk/membrane analogue forming system, generally indicated at 20, that can be used to form composite, yolk/membrane analogues.
  • a single extrusion is herein referred to as a "single extrusion" system and, is described in connection with FIGS. 2, 3 and 4A through 4C.
  • the liquid yolk and liquid membrane forming ingredients can be: i) partially or completely frozen or otherwise immobilized; ii) extruded in a solid or semi-solid frozen and/or immobilized state; iii) cut or otherwise separated int discrete segments having a volume comparable to that of a natural egg yolk; and iv), dropped or otherwise deposited in a setting bath.
  • the exemplary single extrusion system 20 includes two (2) independent, generally parallel component make-up lines — a yolk/membrane make-up line, generally indicated at 21, and an egg white make-up line, generally indicated at 22. These two processes merge into a packaging/output line, generally indicated at 24.
  • the initial processing station in the exemplary yolk make-up line 21 comprises a yolk make-up station 25 in the form of a tank or other receptacle within which various ingredients used to form both the yolk analogue and the membrane analogue are mixed.
  • the ingredients used to form the yolk analogue portion of the composition may include the materials necessary to impart to the finished yolk analogue its appearance, consistency, cooking characteristics, taste and similar organoleptic properties.
  • the membrane forming ingredients included in the single extrusion formulation which is mixed in tank 25 include membrane forming components capable of forming a thin membrane surrounding the yolk analogue slurry upon reaction between certain of the membrane forming ingredients and a suitable setting agent contained in a setting bath.
  • One or more baths may be set in stages, a first stage at ambient temperature, a second heated stage and, if desired/ a third stage at ambient temperature—maintained in a downstream yolk forming station, here designated 26.
  • the membrane forming ingredients included within the liquid formed in tank 25 further preferably include more than one membrane forming ingredient which may be heat responsive and which, when extruded into the setting bath in the yolk forming station 26, forms a relatively thin, strong, liquid-impervious membrane in conjunction with the first membrane forming ingredient.
  • the liquid yolk material is transferred via line 27 to the downstream yolk forming station 26, for example, by a means of a conventional pump 28.
  • the yolk forming station 26 comprises a tank which may contain a continuously recirculated aqueous setting bath, preferably maintained at an elevated temperature, e.g., equal to or greater than about 159° F. and a mild acid pH, e.g., about 6.2 to 6.5.
  • the bath contains the setting agent or agents required to interact with the membrane forming ingredients in the yolk formulation, e.g., about 0.5% to about 1.0% calcium chloride by weight with or without an acid.
  • the yolk forming station 26 may comprise a 2-stage or 3-stage system having: 1) a first stage aqueous setting bath containing, for example, calcium ions and/or other setting agents, maintained at tepid conditions—e.g., about 85° F. to about 105° F.; and ii) a second stage heated bath for increasing the viscosity and/or coagulating heat responsive membrane ingredients in the yolk formulation; and iii), if desired, a third stage tepid bath for insuring that the membrane is firmly set prior to subjecting it to downstream cold water rinses, etc.
  • a first stage aqueous setting bath containing, for example, calcium ions and/or other setting agents, maintained at tepid conditions—e.g., about 85° F. to about 105° F.
  • a second stage heated bath for increasing the viscosity and/or coagulating heat responsive membrane ingredients in the yolk formulation
  • iii if desired, a third stage tepid bath for insuring that
  • the first stage of the yolk forming station 26 further includes an exemplary single extrusion forming system which is not shown in FIG. 2; but which is described in connection with FIGS. 3 and 4A through 4C, within such extrusion system is submerged in the setting bar ' ⁇ and directly coupled to line 27.
  • the yolk As the yolk material is extruded into the setting bath in discrete globules, a membrane is formed surrounding the globule of liquid yolk material as a result of a reaction between the film forming ingredients contained in the yolk material and the setting agent.
  • the yolk (and membrane) is permitted to reside within the bath in a single bath system for a sufficient length of time— generally from about seven to about twelve minutes—to insure that the forming ingredient(s) contained within the yolk formulation form a membrane surrounding the liquid yolk material.
  • the yolk assumes a generally spheroidal configuration as indicated diagramatically at 29-, a configura ion comparable to that of a natural yolk.
  • the yolk/membrane analogues are permitted to reside in a first stage tepid bath from about three to about five minutes to insure formation of the membrane; and to reside in a second stage heated bath for an additional period of about three to about five minutes. And, where a third stage tepid setting bath is provided, the yolk/membrane analogues are allowed to reside therein for a sufficient period of time—e.g., from the order of two to about four minutes—to insure that they are cooled and the membranes are conditioned to tolerate more severe, colder downstream processing.
  • the yolk analogues may then be conveyed in any suitable manner over line 30 beneath a spray rinse nozzle 31 capable of rinsing and washing the individual yolk analogues with a water spray maintained at any suitable temperature e.g., approximately 45° F. to 52° F., so as to temperature adjust the analogues, speed up setting thereof, remove excess setting ions from the surface thereof, etc.
  • the sprayed yolk analogues may then be delivered to a first rinse/set station which. In the exemplary system, may take the form of a shallow tray 32.
  • the yolk analogues may be maintained in the rinse/set shallow tray 32 for any acceptable period, e.g., approximately ten to twenty minutes in a circulating rinse bath maintained at any acceptable temperature, and at a mild acid to neutral pH. During this period of time, the liquid yolk/membrane analogues may rest on the bottom of the shallow rinse/set tray 32, and, therefore assume a yolk-shaped configuration having a flattened bottom as diagramatically indicated at 33 in FIG. 2— i.e., a shape comparable to that of a natural liquid egg yolk when placed on a flat surface.
  • the partially set, but still somewhat soft, discrete yolk analogues may be conveyed in any suitable manner via line 34 beneath an optional second spray rinse nozzle 35 where they are sprayed with cold water, e.g., about 32° F. to about 42° F., and delivered to a shallow rinse/firm/set station or a tray 36 where the liquid yolk/membrane analogues reside in a continuously recirculating rinse bath maintained at any acceptable temperature, e.g., about 32° F. to about 42° F. and at any acceptable pH, e.g., about 6.3 to about 6.8. During this period of time, e.g., up to about 30 minutes, the yolk analogues further assume the relatively firm yolk- shaped configuration as indicated diagrammatically at 37 in FIG. 2 with the fully set membranes now being sufficiently strong to permit handling thereof.
  • any acceptable temperature e.g., about 32° F. to about 42° F.
  • any acceptable pH e.g., about 6.3 to about 6.8.
  • the yolk analogues may be packaged with any suitable egg white material, such as natural egg white, treated egg white or an egg white analogue. In some instances it may be desirable to package at the fabrication facility where the yolk/membrane analogues are formed. Where this is the case, the yolk/membrane analogues may optionally be conveyed by any suitable means over line 38 beneath a spray nozzle 39 where they may be surface dusted with at least one material—for example, HPMC, locust bean gum, carrageenan, and/or mixtures thereof— which promote and enhance thickening and "bunching up" of the egg white around the yolk of the egg and adhesion between the membrane analogue and the egg white material. Thereafter, the surface dusted liquid yolk/membrane analogues are conveyed into a packaging station with the egg white material.
  • any suitable egg white material such as natural egg white, treated egg white or an egg white analogue.
  • the yolk/membrane analogues may optionally be conveyed by any
  • the thickening agent(s) may be formed into a liquid solution with the yolk/membrane analogue being sprayed or dipped therein, or the liquid solution may be added directly to the egg white material itself.
  • the material is further processed-for example, when pasteurized and/or thermostabilized—the egg white thickens and resumes a natural thick consistency replicating that of the white in a freshly laid natural poultry egg.
  • the discrete liquid yolk/membrane analogues may be ship to conventional processing facilities for combining with natural egg white.
  • Both the egg white make-up line 22 and the packaging/output line 24 could be located at the processing facilities, rather than the facilities of the liquid yolk analogue fabricator.
  • the liquid yolk/membrane analogues may be conveyed from the rinse/firm/set station 36 over line 38a to a freeze station 41 where the liquid yolk/membrane analogues are frozen for shipment.
  • the frozen liquid yolk/membrane analogues are, upon arrival at the processing plant, passed beneath nozzle 39 and Into the packaging station 40 or treated in any of the above- described alternative ways.
  • the egg white make-up line 22 (which may be locate at either the same facility where the liquid yolk/membrane analogues are fabricated or at an egg cracker's facility) includes an egg white make-up station 42 which may simply be a storage repository for natural egg white, or in which simulated egg white analogue can be synthesized. In either case, a solution of HPMC, locust bean gum and/or carrageenan may be included with the egg white material in the make-up station 42 to enhance thickening of the egg which during later processing.
  • the egg white material is then preferably conveyed via line 44 from the egg white make up station 42 to a pasteurization or thermostabilization station 45; and, from there via line 46 to the packaging station 40 where the egg white material fixedly attaches itself to the outer surface of the membranes.
  • the whole poultry egg analogues can be individually packaged in any desired form—for example, individually, in six-packs, in twelve-packs, etc.—and, if desired, in a nitrogen or partial nitrogen atmosphere.
  • the packaged whole egg analogues are then conveyed via line 48 through an optional second stage pasteurization or thermostabilization station 49; and, via line 50 to an option storage station 51 where the egg analogues can be maintained for any desired period of time.
  • the whole poultry egg analogues are then ready for delivery to distributors, wholesalers and/or retailers as indicated generally at 52.
  • FIGS. 3 and 4A through 4C disclose structural components which may be submerged within a setting bath contained within the yolk forming station 26. As the yolk material enters the forming station 26, it is, in this case, extruded directly into the setting bath. This permits a reaction to occur between the membrane forming ingredients contained within the yolk material and the setting compounds contained within the bath.
  • the exemplary single extrusion yolk/analogue forming system may include a generally cylindrical, soft, flexible extrusion nozzle 54, which is mounted on the free upper end of the slurry input line 27 coupled to pump 28.
  • the extrusion nozzle is preferably formed of a resilient, soft rubber or rubber-like thermoplastic material.
  • An interrupter assembly, generally indicated at 56, is provided having a central hub 57 and a pair of radiating, round, rigid, interrupter rods 58 extending in opposite directions from the hub 57, which rods may be formed of steel or other suitable rigid metal or plastic material.
  • the arrangement Is such that the illustrative interrupter rods 58 lie in a plane normal to a vertical axis extending through the extrusion nozzle 54, with the rods 58 being positioned to engage and flex the upper end of nozzle 54 upon rotation thereof—for example, rotatio- in a counterclockwise direction as viewed in FIG. 3.
  • hub 57 is coupled via drive shaft 59 to a unidirectional motor "M" which can be submersible and contained within the setting bath in yolk forming station 26 or which can be mounted externally to the bath.
  • the liquid yolk material containing the membrane forming ingredients is extruded into the heated setting bath through nozzle 54, it begins to form a somewhat globular shape 61.
  • the outer surface of the globular shape is in face-to face contact with the setting bath from the instant of extrusion into the bath.
  • one of the driven rotating interrupter arms 58 engages the nozzle 54 (the upper left edge as viewed in FIGS. 4A through 4C) and serves to deform the nozzle.
  • the discharge opening through which the slurry 60 is passing changes from round, as shown in FIG. 4A, to a somewhat curvilinear slot, as shown in FIG 4B. This pinches off the globule 61 from the main body of yolk material being extruded through nozzle 54 and inlet line 27.
  • the outer surface of the globule 61 has, of course, been in direct contact with the setting agent(s) in the bath from the instant when the yolk material 60 first exited nozzle 54.
  • the setting agents interact with the membrane forming ingredients contained within the yolk material.
  • the viscosity of the heat membrane forming ingredients increases.
  • the film forming material coagulates solidifies, crosslinks, etc. and an increasingly strong, thin, liquid-impervious membrane is formed about the surface of the globule 61.
  • a pair of slight protuberances 62 may form at diametrically opposite ends of the extruded globule 61.
  • the two slight protuberances 62 may closely simulate, in appearance the chalazae 16 (FIG. 1) present in a natural poultry egg.
  • a residence time of from about seven minutes to about twelve minutes in the setting bath and/or in a multi-stage setting bath in yolk forming station 26 is sufficient to insure formation of a relatively strong, stable, membrane surrounding the globule 61.
  • the interrupter rod clears the soft flexible extrusion nozzle 54—i.e., as the rod 58 continues to move to the right from the position shown in FIG. 4C— the nozzle 54 springs back to the cylindrical configuration shown in FIG. 4A.
  • the yolk/membrane material 60 continues to be extruded therefrom so as to form multiple yolk/membrane analogues in sequential order.
  • the size or volume of the yolk/membrane analogues formed with the system such as depicted in FIGS. 3 and 4A through 4C may vary with the diameter of the nozzle 54, the speed with which the yolk material 60 is extruded from the nozzle 54, the rotational speed of the interrupter arms 58 and the number of interrupter arms 58 mounted on hub 57. Generally, however, such variable parameters will be preset so as to produce yolk membrane analogues weighing approximately sixteen grams. Where desired, the apparatus described above may employ multiple input lines 27 terminating in multiple parallel soft flexible ejection nozzles 54 which are sequentially flexed by rotation of the interrupter assembly.
  • the yolk forming material may be partially or thoroughly frozen in an extrudable condition, such as in the case of soft ice cream.
  • the membrane setting solution into which the yolk and membrane material are extruded should be at an elevated temperature, e.g. about 160° F. This elevated temperature, taken in conjunction with the bath components, is useful for setting the membrane which contains the yolk.
  • the yolks with their attendant membranes may be removed from the setting bath and placed into an optional wash, useful for removing excess membrane forming ions from the surface of the membrane.
  • the yolks may then simply be removed from the bath and placed into natural egg white or an egg white analogue as described above.
  • the washes may comprise water or any other non-reactive fluid, and typically are at a temperature ranging from about room temperature to as low as about 32° F.
  • Preferred single extrusion formulations include the following:
  • flavorants 0 to 15.0 thickeners 0.1 to 3.0 fats/oils 0.1 to 15.0 water 50.0 to 98.0 emulsifiers 0.01 to 1.0 film-formers 1.0 to 5.0 cross-linkers 0 to 1.0 protein 0 to 2.0
  • flavorants 1.0 to 5.0 thickeners 1.0 to 12.0 fats/oils 15.0 to 50.0 water 25.0 to 70.0 emulsifiers 0.5 to 5.0 deaerators 0.1 to 2.0 heat releasable ions 0.5 to 2.0 chelaters/complexers 0.001 to 0.5 proteins 1.0 to 10.0
  • the yolks with or without the attendant egg white material may then be sterilized or pasteurized by appropriate methods, e.g., heat pasteurization, sulfur dioxide, ultraviolet light sterilization and the like.
  • appropriate methods e.g., heat pasteurization, sulfur dioxide, ultraviolet light sterilization and the like.
  • the ingredients and/or the components may be pasteurized or sterilized prior to analogue formation and the composition formed under sterile or clean conditions.
  • composition described herein may use components selected to provide variable viscoelastic properties for the yolk and its attendant membrane over a wide range, such as a finished whole or scrambled egg analogue which will stay soft and moist even if overcooked.
  • the composition may be formulated to harden and become rubbery in cross-section with relatively little cooking. Hence, great variation in the end product is possible by following the teachings herein.
  • lactic acid l.Og
  • the lactic acid acts as a buffer and flavorant. Then treat the composition as described -above, freezing into an appropriate number of frozen "patties".
  • Part B Membrane Formulation Egg White 150.0 ml.
  • This composition may be set aside (2 to 3 hours) or treated with a vacuum deaerator to remove any air.
  • Soy lecithin (Fearn Co.) 2.0 ml. sodium alginate (Kelgin LV) 1.5 g. water 12.0 ml.
  • Lactic Acid (All World Scientific Co.) 8.0 g. Water q.s. ad. 1200 mis.
  • HPMC locust bean gum
  • Kelco Div. Merck & Co. Sodium Alginate (Kelcogel LV, Kelco) 7.0 g.
  • Beta-Carotene (Hoffmann la Roche) q.s.
  • Part C Setting Bath Water 300.0 ml.
  • a whole egg analogue synthesized using this yolk analogue will have medium viscosity and will be more resistant to hardening, suitable for general purpose preparation.
  • the lactic acid contained in the reactant fluid assists in forming the containment membrane and enhancing the poultry flavor.
  • Silicone Antifoam (S.A.G. 710) 1.0 g.
  • the yolk analogue may then be incorporated into a whole egg analogue by adding to natural synthetic or treated egg white. It will yield a thin, flowing yolk upon rupture of the containment membrane.
  • Chicken Broth (Swanson Clear Broth) 1000.0 ml. Chicken Meat (Holly Farms) 70.0 g.
  • This yolk may be cooked to form-a soft boiled or hard boiled yolk which may be eaten whole or incorporated into egg salad, or used to form "tube eggs” for institutional use in sandwich making.
  • Safflower Oil Margarine 115 .0 g. (Wilsey Foods, Inc.) Collagen (Geo. A. Hormel & Co.) 90, .0 g- Magnesium Sulfate 1, .0 g- Calcium Carbonate 1, .0 g- Beta-Carotene q.s.
  • the yolk prepared may have more firmness than the yolk of example 4 apparently based on the higher concentration of divalent ions.
  • Methylcellulose (A4M Dow Che . Co.) 9.0 g.
  • This yolk is capable of being supported by a delicate containment membrane, being semi-solid while ref igerated. This characteristic results in less pressure being exerted against the containment membrane while the egg analogue is stored. It also results in a very normal egg yolk appearance when assembled into a whole egg analogue.
  • Adipic Acid (Monsanto) 3.0 g.
  • Beta-Carotene (Hoffmann la Roche) q.s.
  • the yolk formulation is immobilized and used with any selected membrane formulation, to form a slow-hardening yolk analogue.
  • Part 2 Denatured Egg Albumin 40.0 g.
  • part 2 Combine the ingredients of part 2 in a high speed blender and blend for 1 to 2 minutes. Add parts 1 and 2 together in a food processor and blend for an additional 5 to 10 minutes. Add beta carotene to dye the composition as desired.
  • This composition may be used to coat immobilized yolks, after which the coated yolks are placed into a setting bath.
  • Soy Milk (Erie Casein Co.) 250.0 g.
  • Carboxymethylcellulose (Dow Chem. Co.) 100.0 g.
  • glyceraldehyde may be included in the setting bath in addition to a calcium salt.
  • ammonium hydroxide in the coated yolks may be neutralized with a mild acid vapor or acid bath.
  • Silicone antifoam (S.A.G. 710) 1.0 g.
  • Part B Setting Bath
  • a preferred setting bath for the coating formulation of Example 12 is set forth below.
  • Lactic acid (All World Scientific Co.) 80.0 ml.
  • Pre-gelatinized rice flour (Riviana) 30.0 g.
  • Beta carotene (Hoffmann la Roche) q.s.
  • Lactic acid 8.0 g.
  • This yolk formulation provides a non-reactive yolk, which does not solidify, even upon prolonged cooking. If the acid used herein imparts a sour taste to the yolks, it may be necessary to reduce the acid components in the bath by as much as 80 percent to eliminate the sour taste.
  • Corn oil margarine (Fleischman 1 s) 140.0 g.
  • Beta carotene q.s. FDC Yellow No. 5 (Chroma Kote, q.s. T 815y, Crompton & Knowles Corp.)
  • Part B Membrane Formulation Water 400 . 0 ml .
  • Oil soluble yellow food dye q . s . (Chroma Kote)
  • Pre-gelatinized rice flour 15.0 g- (Riviana Foods, Inc.) Uncooked chicken breast 4.0 g- Sodium phosphate dibasic 1.0 g- Ammonium hydroxide 1.0 ml Kelcogel LV 5.0 g- Glycerol 5.0 g- Silicone (S.A.G. 710) 2.0 g- Egg whites 75.0 ml
  • This formulation provides a thin yolk with moderate reactivity.
  • Pre-gelatinized rice flour 15.0 g.
  • the yolk formulation After mixing the yolk formulation, it may be pasteurized prior to the molding and immobilizing steps. The yolks are then molded and frozen.
  • the immobilized yolks are dipped in a membrane formulation, and then treated with a setting solution at about 140°F for about 5 minutes, until the membrane sets.
  • the yolks are placed into one or more washing baths then surface dried.
  • the yolks are then added to conventional egg white, treated egg white or an egg white analogue.
  • Methylcellulose (A4M Dow Chemical) 5.0 g.
  • Corn oil margarine (Fleischman's) 115.0 g. Silicone (SWS Silicones Corp. No. 211) 1.0 g.
  • freeze the remaining 150 ml. chicken broth In a container, freeze the remaining 150 ml. chicken broth. Then add frozen broth or otherwise cool to bring temperature down to less than 20°C and blend for 20 minutes or until methylcellulose is completely dissolved.
  • the foregoing batter may be freed of entrained air by heating the batter in a microwave slightly and allowing all air to escape before forming into yolks.
  • This yolk formulation forms hard yolk analogues, which simulate the texture of the yolks of hard boiled eggs. It is therefore useful as a hard boiled whole egg analogue, egg salad or deviled egg analogues when combined with white.
  • Soy protein (Chemurgy Co.) 20.0 g.
  • the membrane coating formulation should be freed of entrained air before use.
  • An egg analogue made utilizing the higher calcium content in the setting bath will form a hardened yolk when cooked.
  • the hardened yolk is very similar in all respects to natural hard cooked egg yolk.
  • This egg analogue makes excellent hard-yolk cooked fried eggs, sandwiches, such as fried eggs or tube egg. It also makes hard boiled eggs, such as for eating or making egg salad, potato salad, or deviled eggs.
  • Lecithin (Fearn Co.) 6.0 g.
  • Xanthan gum (Kelco) 2.0 g.
  • Unsalted margarine (Wilsey) 115.0 g.
  • Locust bean gum (Hi Tek Polymers, Inc.) 2.00 g. Water 12.00 ml.
  • Carrageenan (Sea Gel FL 674P) 1.75 g. Locust bean gum (Hi Tek Polymers, Inc.) 1.0 g.
  • Unsalted margarine (Wilsey Foods) 57.5 g.
  • Clintose LV (ADM Corp.) 1 . , 20
  • Lecithin Central Soya
  • Locust Bean Gum HiTek Polymers
  • Beta carotene (Hoffmann laRoche) 0 , . 07
  • Lactic acid (All-World Scientific) 1.5 g
  • the chicken broth, reduced to about 12.0 ml, a solids content of approximately one and one-half percent (1.5%), by weight, and sodium alginate LV were alter ⁇ ately blended and allowed to rest for periods of about two to about three minutes—for a period of approximately ten minutes.
  • the soy lecithin, egg white, chicken fat and margarine are then added to the chicken broth/algin mix and homogenized at high speed for about three to about five minutes so as to reduce the foaming characteristics of the mix.
  • the lactic acid and sodium citrate are added, and the overall mix is blended for two to three minutes. Add the locust bean gum and blend the overall mix enough to get good dispersion. Add sufficient beta carotene to color the yolk/membrane analogue composition to "No. 7" on the Roche Yolk Colour Fan.
  • the resulting composition may be pumped through an extrusion nozzle as shown in FIGS. 3 and 4A through 4C into a first tepid setting bath maintained at a temperature ranging from about 105° F. to about 110° F., containing water and about 0.5% to 0.75%, by weight, calcium chloride.
  • the extruded slurry is separated or pinched off by interrupter rods 58 (FIGS. 3 and 4A through 4C) into discrete globules.
  • variable parameters of the single extrusion system may be adjusted to produce discrete globules weighing approximately eighteen grams each, with there being sufficient slurry to produce eighteen separate discrete globules.
  • the globules are permitted to reside in the tepid bath for from about three minutes to about five minutes, during which period the sodium alginate LV reacted with the calcium ions present in the bath to form a thin algin matrix or membrane surrounding the liquid yolk material.
  • the discrete yolk-like spheroidal globules are transferred to a recirculating heated bath maintained at a temperature greater than 159° F. where they are permitted to reside for an additional period of from about three (3) to about five (5) minutes.
  • the discrete yolk analogues are then transferred to a continuously circulating tepid water rinse/set bath maintained at a temperature level ranging between about 85° F. and about 105° F. and a pH of between about 6.4 and about 6.8 and are thoroughly rinsed and excess calcium and acid were removed.
  • the discrete yolk/membrane analogues may be removed from the tepid rinse/set bath, rinsed with cold water at a temperature between about 45° F. and about 52° F. to further assist in removing excess calcium and acid, and transferred to a shallow rinse/set tray 32 (FIG. 2) maintained at a temperature of between about 45° F. and about 52° F. and a pH of between about 6.4 and about 6.8.
  • the discrete analogues are removed from the tray 32, again rinsed with cold water at a temperature of from about 32° F. to about 42° F. , and transferred into a second rinse/firm/set tray 36 (FIG. 2) containing a cold water rinse bath maintained at a temperature of from about a cold 32° F. to about 42° F. and a pH of from about 6.3 to about 6.8 for a period of from about ten (10) minutes to about thirty (30) minutes.
  • the yolk/membrane analogues are surface dusted with a mixture of equal parts of HPMC and locust bean gum and then placed in natural liquid egg white contained within suitable cups--there being approximately thirty-six grams (36 gr.) of egg white material in each cup, producing a whole liquid poultry egg analogue weighing approximately fifty-four grams.
  • a yolk formula suitable for use in preparing composite, integral whole liquid poultry egg analogues with a dual extrusion system is prepared in the following manner, utilizing the following ingredients:
  • Pregelatinized rice flour 9 Pregelatinized rice flour 9 . Og (Riviana Foods, Inc.)
  • the resulting mixture is suitable for feeding into a conventional extrusion system employing a central extrusion nozzle of the type commonly used in forming relatively thick soft ice cream.
  • a central extrusion nozzle of the type commonly used in forming relatively thick soft ice cream.
  • an outer annular extrusion nozzle concentric with the central nozzle is used for extruding a setable composition membrane in surrounding relation to the liquid yolk core material.
  • Such components are extruded into a suitable setting bath.
  • Locust bean gum (Hi Tek) 9.0g.
  • the water, locust bean gum and sodium alginate are placed in a blender and homogenized for approximately five minutes.
  • the resulting blended ingredients are stirred to minimize the amount of entrained air.
  • the yolk analogue slurry and the membrane analogue slurry may be coextruded into a suitable setting bath as described above.
  • Example 31 may be modified, and the locust bean gum is reduced from nine grams to six grams and supplemented by 1.5 g. of gum tragancanth. After prolonged storage, the thus modified whole poultry egg analogues look and handle in essentially the same manner as a natural fresh whole poultry egg. Similar results can be achieved using carrageenan, methylcellulose and/or guar gum in lieu of gum tragancanth; or, when using a protein as described in Example 28.
  • Example 32 is particularly suitable for use with the membrane described above in Example 31.
  • the following membrane formulation can be used:
  • the sodium phosphate dibasic and ammonium hydroxide function as protein solubilizers for the chicken meat.
  • the ammonium hydroxide also increases the pH level of the mix.
  • blend water (200.0 ml) sodium alginate LV, guar gum and silicone.
  • a membrane suitable for use with virtually any of the foregoing frozen yolk analogues is prepared in the following manner, using the following parts and ingredients:
  • Part 1 water 198.0 g pepsin (1-15,000) (Schwartz Svcs, 2.0 g Int.)
  • Part 2 dry, powdered, fat free milk 71.2 g and water (10% solution) (Ettlinger Corp.) hydrochloric acid 0.1 g lactic acid 0.4 g
  • Scalding bath containing an aqueous solution of 1% alum and maintained at a temperature above 159° F.
  • the frozen patties are dipped into Part 1 and frozen. After freezing they are dipped into Part 2 and refrozen. These two (2) steps are repeated three or four times.
  • the coated frozen egg yolk analogues are dipped into Part 3, thus serving to irreversably inactivate the pepsin and toughening the milk protein.
  • the alum acts as a cross-linking agent.
  • the resulting product can be frozen until combined with liquid egg white, at which point the membrane may preferably be surface dusted with a mixture of HPMC, locust bean gum, acacia gum, guar gum and/or carrageenan and combined with the liquid egg white as previously described.
  • HPMC five percent
  • locust bean gum and/or other gums can be added to the protein solution to form a thicker membrane and reduce the need for multiple dipping.
  • Another membrane analogue that can be utilized with any of the foregoing frozen egg yolk analogues includes the following ingredients:
  • the frozen egg yolk analogues are then dipped into the foregoing coating solution and refrozen.
  • the ammonium hydroxide evaporates, setting the albumen in a membrane surrounding the yolk.
  • the membrane contains essentially a proteinaceous hydrocoloid—viz. , boiled egg white.
  • the solubilized protein is set into a durable sac-like membrane as the ammonium hydroxide evaporates.
  • an acid component can be included in the yolk, or the coated yolk can be dipped in an acid, so that the acid component will combine and react with the ammonium hydroxide to enhance membrane formation.

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  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Nutrition Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Botany (AREA)
  • Molecular Biology (AREA)
  • Meat, Egg Or Seafood Products (AREA)

Abstract

La présente invention se rapporte généralement à un produit alimentaire comestible. Un analogue d'oeuf entier est décrit, dans lequel un analogue de jaune d'oeuf est traité pour former une membrane sur sa surface externe. Le jaune d'oeuf avec sa membrane associée est combinné avec un blanc d'oeuf naturel, blanc d'oeuf traité ou un analogue de blanc d'oeuf pour former l'analogue d'oeuf entier. Un appareil servant à former un analogue de jaune d'oeuf est décrit, dans lequel sont compris une extrudeuse avec une buse déformable (54) et un organe d'arrêt (58) servant à interrompre l'écoulement de la substance constituant le jaune d'oeuf à partir de la buse de l'extrudeuse.
EP19890905888 1988-05-06 1989-05-05 Whole egg analogue composition and method Withdrawn EP0417142A4 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US19088588A 1988-05-06 1988-05-06
US190885 1988-05-06

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EP0417142A1 true EP0417142A1 (fr) 1991-03-20
EP0417142A4 EP0417142A4 (en) 1991-11-06

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AU (1) AU3569889A (fr)
WO (1) WO1989010704A1 (fr)

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Publication number Priority date Publication date Assignee Title
JPH10257868A (ja) * 1997-03-19 1998-09-29 Nippon Nousan Kogyo Kk 全卵様食品
EP1145649A1 (fr) * 2000-04-13 2001-10-17 Oldenburger Fleischwaren GmbH Procédé pour la fabrication d'un produit à base d'oeuf
ES2320539T3 (es) * 2002-07-03 2009-05-25 Wade Mussawir-Key Frederick Substitutos del huevo.
US20150313269A1 (en) * 2014-05-05 2015-11-05 Aniceto González Rodríguez Egg substitutes and methods for making the same
WO2023094536A1 (fr) 2021-11-25 2023-06-01 Neggst Foods Gmbh Produit végan de substitution du jaune d'oeuf
DE102021130963A1 (de) 2021-11-25 2023-05-25 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein Eiklar-Ersatzprodukt auf veganer Basis
DE102021130974A1 (de) 2021-11-25 2023-05-25 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein Eigelb-Ersatzprodukt auf veganer Basis

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US3769404A (en) * 1970-10-12 1973-10-30 Anheuser Busch Egg composition
US3941892A (en) * 1974-07-01 1976-03-02 General Foods Corporation Low-cholesterol egg product and process
US4182779A (en) * 1977-12-05 1980-01-08 Stauffer Chemical Company Egg yolk extender
US4251201A (en) * 1978-09-18 1981-02-17 Krysiak Janusz D Extrusion apparatus
US4362748A (en) * 1980-10-03 1982-12-07 Loyal Wells Method for forming shaped products for human and/or animal consumption or as marine bait and products produced thereby
JPS5916742B2 (ja) * 1981-04-02 1984-04-17 レオン自動機株式会社 粘性物の包み成形機
US4469475A (en) * 1983-07-01 1984-09-04 Krysiak Dobroslaw J Machinery for making encrusted food products
JPS6121070A (ja) * 1984-07-11 1986-01-29 Q P Corp 魚卵様食品の製法

Non-Patent Citations (2)

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Title
No further relevant documents have been disclosed. *
See also references of WO8910704A1 *

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WO1989010704A1 (fr) 1989-11-16
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