Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/14—Vegetable proteins
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
  • A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
  • A23L33/17—Amino acids, peptides or proteins
  • A23L33/185—Vegetable proteins
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
  • A23L33/20—Reducing nutritive value; Dietetic products with reduced nutritive value
  • A23L33/21—Addition of substantially indigestible substances, e.g. dietary fibres
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
  • A23L7/10—Cereal-derived products
  • A23L7/115—Cereal fibre products, e.g. bran, husk

Definitions

• This patent relates to high and intermediate protein textured extruded products from food-grade biomaterials with brans and plant fibers as dispersed phase fillers for application as food substitutes in food service-prepared, processed or manufactured foods in the forms of extenders, fillers, and analogs.
• the physical characteristics of the extrudates with brans and plant fibers as dispersed phase fillers define the various food applications of the extruded products in cooked or processed meat, vegetable, fruit, fish and fishery recipes and products.
• the changes in physical structures of the extrudates with the addition of brans and plant fibers influence variations in length, diameter, radial expansion, porosity parameters, bulk density, hydration yield, and fiber characteristics of the extruded food-grade biomaterials.
• extrudate is the resulting processed product of extrusion processing that is essentially based on the conversion of carbohydrates and protein biomaterials to well-defined structured textured materials.
• the extruder hardware can convey, compress, melt, and plasticize biomaterials (van Zuilichem, 1992;
• extrudate oscicki, 2011
• extruder barrel a textured product of defined expansion and density.
• the structure forming components of an extrudate are carbohydrates and proteins. These two ingredients represent the major bulk of components in an extrudate recipe.
• the common protein ingredients for extrusion may include soy, wheat, and other high- protein legume-based proteins.
• carbohydrates used in extrusion processing are starches and flours from cereals, tubers, and roots. Elevated temperatures and shear with limited water melt starches during extrusion (Wang, 1993; Qu and Wang, 1994; Hoover, 2001) while further increase in moisture content may effect gelatinization of starch during extrusion (Lawton et al., 1972; Chiang and Johnson, 1977; Mercier, 1980; Guy and Home, 1988; Wang et al., 1991; Mitchell and Areas, 1992; Parker and Ring, 2001). Carbohydrate conversion is also affected by the presence of other components, such as proteins.
• starch- protein complexes help define the textural quality of the resulting extrudates that would be developed in any viscoelastic melt (Madeka and Kokini, 1992; Mitchell and Areas, 1992; Li and Lee, 1996;).
• the carbohydrate matrix may form a discontinuous phase interacting with the more continuous fibrous phase of the proteins (Tolstoguzov, 1993; Tolstoguzov et al., 1985).
• extrusion processing allows the development of biphasic matrices in the melt.
• the carbohydrate matrix may consist of mixture of gelatinized starch and mostly melted starch components that may have been mechanically and thermally degraded in the extruder (Donovan, 1979; Wang et al., 1991).
• extrudate swell variably (Padmanabhan and Bhattacharya, 1989; Chang, 1992; Housiadas and Tsamopoulos, 2000).
• the die swell phenomenon has been reported to manifest the following: superheated water is released from exiting melt (Harper, 1981), loss of moisture increases the viscosity of the melt (Chang, 1992; Delia Valle et al., 1997), and there is the instantaneous expansion of melt as it exits the die followed by setting into a glassy state during of the cooling direct expanded products (Park, 1976; Guy, 2001).
• Expanded extrudate can be considered a form of cellular solid forming honeycombed structures (Moscicki, 2011). These structural formations have a plurality of openings and passages of desired sizes or shapes (Bagley, 1974) with cell walls defining the boundaries of each pore.
• Honeycombed structures of extrudates comprise of interconnected pores. Porosity, which is a significant criterion for hydration capacity (Zhang and Hoseney, 1998) and textural characteristics of extrudates, indicates the volume fraction of void spaces or air spaces inside a cellular solid material like the expanded extrudate (Lukkassen and Meidell, 2008). Void cell structures of an expanded extrudate seem to be directly related to the number of bubbles nucleated in a melt (Lue et al., 1990). The bubble nucleation phenomenon in plant polymer extrusion includes the formation of small, thermodynamically unstable gaseous embryos within the viscoelastic melt.
• nucleus This gaseous embryo reaches critical size and grows spontaneously into a stable and permanent bubble called nucleus (Cisneros, 1999). Nucleation sites in expanding viscoelastic melt may be seeded by insoluble materials that do not transform during extrusion (Hooseney et al., 1992; Cisneros and Kokini, 2002a,b; Kokini and Moraru, 2003) like the dispersed phase fillers.
• extruded textured food biomaterials are traditionally derived from plant-based sources of carbohydrates and proteins.
• the traditional use of extrudate as an ingredient in processed meat is 3-tiered: extender, filler, and analog.
• High protein-based extruded materials can either function as a meat extender or a meat analog since it would have the fibrosity, appearance, and mouthfeel of meat products.
• extender When used to extend expensive meat materials, it is added in combination with the meat ingredients to lower down the cost of a prepared and processed meat formulation (Harper, 1981; Heinz and Hautzinger, 2007).
• extrudates are used as an analog, all meat materials are substituted with plant-based extrudates.
• extrudates When used as extender or analog, extrudates should closely resemble real meat in physical form and mouth feel (Sheard, et al., 1984; Rareunrom et al., 2008). When extrudates are less protein-rich and consist more of carbohydrates, these extrudates can be used as fillers (Heinz and Hautzinger, 2007). The function of extrudates as fillers does not necessitate the presence of meat-like characteristics since the extrudates are eventually used in highly homogenized food systems like meat emulsions or doughs. As bulking agents, extrudates can be at the same rank as starches and flours in food systems to provide volume (Heinz and Hautzinger, 2007). However, textured fillers have the additional benefit of providing more stable rheology than the bulking powders.
• Dispersed phase filler An ingredient of the extrusion formulation that is often considered as minor ingredient is the dispersed phase filler. These are materials which relatively hard to solubilize in water. Dispersed fillers may constitute aggregates of proteins that are denatured and deformed or some fibrous material added to extrusion formulae such as cellulose or bran (Guy, 2001). These fillers are cited to be firm, and stable ingredients that are not necessarily reduced in its size during extrusion (Lawton et al., 1985). Filler ingredients can affect the expansion of extrudate by influencing the die swell.
• the die swell and the elastic recoil of the elastic melt as it exits the orifice of the die is attributed to the innate elasticity of the major biomaterials of the melt (Moraru and Kokini, 2003).
• the elastic energy of the melt is released as it leaves the die and causes the expansion towards the direction of flow of the melt (Guy, 2001).
• the presence of dispersed phase fillers may help deform the elasticity of melt.
• This invention details the contribution of dispersed phase fillers including brans and plant fibers that are used in formulations intended for extrusion.
• the extrudate specific physical criteria in this invention used for the evaluation of dispersed phase filler contribution in extruded products are length, diameter, radial expansion, bulk density, hydration yield, porosity, and fiber characteristics. These parameters will be used to explain the significant function of dispersed phase materials in texturized extruded food grade biomaterials.
• WO 2005/096834 A2 (Brown et al., 2005), disclosed the process of manufacturing vegetable protein extrudates containing high concentrations of protein, and low concentrations of carbohydrates.
• US 7235276B2 (Allen et al., 2007) provided improvements to high protein, and high fiber puffed ready- to-eat cereal products by including adequate amounts of fiber in the formulation in order to decrease the glassy textural attributes and to produce a softer product.
• WO 2009/076136 (Yakubu et al., 2009) related to extruded products containing high levels of soy protein and whole grains, processes for manufacturing such extrudates, and the use of such extrudates as food ingredients.
• a prior art UM 2-2010-000154 (Chu et al., 2010) described the incorporation of stabilized rice bran as dispersed phase filler to enhance the porosity and water hydration capacity of protein-based extruded meat analog and extender products used by food manufacturers and food service companies as high- protein meat substitutes.
• This present invention is the improvement of UM 2-2010-000154 (Chu et al., 2010) with increased use of brans and plant fibers to redefine physical characteristics of high protein and intermediate protein extrudates from food grade biomaterials.
• This invention relates to the use of dispersed phase fillers in the form of brans and plant fibers in extruded textured food grade biomaterials mainly consisting of plant protein and carbohydrate sources.
• the dispersed phase fillers are used to modify the physical characteristics of extruded materials in terms of length, diameter, radial expansion, porosity, bulk density, hydration yield, and fiber characteristics.
• the changes in physical characteristics of extrudates allow diversification of food applications of dispersed phase filler-containing extrudates.
• Blended formulations of the structure-forming ingredients, proteins and carbohydrates, in various combinations are mixed with brans and plant fibers up to 3% incorporation (wt/wt) of composite dry ingredients.
• the plant protein sources may include, but not limited to, cottonseed flour, green pea powder, peanut flour, pea protein isolate, soy flour, soy concentrate, pea protein isolate, and wheat gluten.
• plant carbohydrate sources which include, but not limited to, cassava starch, cornstarch, millet flour, potato starch, quinoa flour, rice flour, rye flour, semolina flour, sorghum flour, tapioca starch, and wheat flour.
• Brans include, but not limited to, oat bran, rice bran, wheat bran, white corn bran, and yellow corn bran.
• Plant fibers include, but not limited to, coconut meat fiber, oat fiber, potato fiber, and soya fiber.
• High protein textured extrudate from food grade biomaterials with greater than 60% calculated theoretical protein content (db) of the dry extrusion base mixes (DEBM) and intermediate protein textured extrudate from food grade biomaterials with 50 to 60% calculated theoretical protein content are illustrated in this invention that may be varied in physical characteristics of the resultant direct expanded products by incorporation of 0.5 to 3.0% dispersed phase fillers.
• the extruded products can still be further subcategorized into cut, granulation, shape, and color series per FoodFlow, Inc. (FFI), Philippines major extrudate categories.
• the high protein extrudates from food grade biomaterials with incorporated brans up to 3.0% are significantly larger in diameter and more expanded radially than those without bran at 5% level of significance. These extrudates also have significantly less number of bigger pores, greater bulk density, and thinner and smoother individual fibers than those without bran at 5% level of significance.
• the length, porosity content, apparent cell wall content, and hydration yield of high protein extrudates from food grade biomaterials with incorporated brans up to 3.0% are similar to those without bran.
• the intermediate protein extrudates from food grade biomaterials with incorporated brans up to 1.0% are significantly longer, smaller in diameter and less expanded radially than those without bran at 5% level of significance.
• extrudates also have significantly more number of smaller pores with less area occupied by pores and consequently, larger area occupied by apparent cell walls, and greater bulk density than those without bran at 5% level of significance.
• the hydration yield and fiber characteristics of high protein extrudates from food grade biomaterials with incorporated brans up to 1.0% are similar to those without bran.
• the high protein and intermediate protein extrudates from food grade biomaterials with incorporated plant fibers up to 3.0% are considered to have the same changes in physical characteristics including length, diameter, radial expansion, porosity, bulk density, hydration yield, and fiber characteristics as what have been recorded with bran incorporation up to 3.0% compared to those without bran.
• High protein and intermediate protein extrudates from food grade biomaterials with incorporated brans and plant fibers up to 3.0% can be subcategorized into colors, forms, cuts, shapes, and granulations, and can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods.
• This patent details the effects of incorporating dispersed phase materials in the form of brans and plant fibers for the production of high protein and intermediate protein extrudates that consist mainly of structure-forming plant-based ingredients.
• the structure-forming ingredients refer to the protein and carbohydrate sources of the extrusion formulation. Blended formulations of the structure-forming ingredients in various combinations are mixed with brans and plant fibers up to 3% incorporation (wt/wt) of DEBM.
• the extrudates with brans and plant fibers are dried to maximum of 10% moisture (db).
• the diameter is the measurement of the line segment passing through the center of circular set structure of the solidified extruded product.
• the length is the measurement from one end to another end of the solidified extrudate.
• the radial expansion ratio is the average ration of cross sectional area of set extrudate to cross sectional area of the die (Choudhury and Gautam, 2003).
• the bulk density refers to the weight per unit volume that may be expressed as g/ml (Lawton et al., 1985). Hydration yield is the hydrated weight to dried weight of extruded material.
• the hydrated weight is the measured weight of extrudate after soaking in water at ambient temperature (28 ⁇ 2°C) for 30 minutes and draining the material for 5 minutes (Yao et al., 2006). Hydration ratio is the expression that quantifies the maximum hydration liquid that a dry extrudate can absorb or retain. Relative to the hydration yield, a part of the dry extrudate is subtracted from the computed yield that corresponds to the hydration liquid.
• Porosity parameters namely the pore density (number of pores per unit area of the examined cross section), porosity content (percent of the cross section occupied by pores), apparent cell wall content (percent of cross section occupied by the material that surrounds the pores and calculated as 100 minus porosity content, %), and mean pore size (average area, mm 2 , occupied by single pore) are evaluated through Pixcavator Image Analysis 6.0 (Intelligent Perception, 2010; Ardhekani and Raiszadeh, 2011). Fiber characteristics such as transparency, crimpling, and thickness are qualitatively described by four panelists based on images taken using Leica EZ4D stereomicroscope (200x magnification).
• the ratio of plant protein source to carbohydrate source in DEB s do not have a direct relationship to the calculated theoretical protein due to variability in protein contents of various plant sources (i.e., isolate soy protein has 90% protein and wheat gluten has 75% protein). Based on the calculated theoretical protein content as working criterion for groupings of FFI, Philippines extrudates, DEBM to produce FFI major extruded products are presented in Table 1.
• Theoretical protein (%) is the summation of supplier declared percent protein of the ingredients in a formulation
• the FFI, Philippines DEBMs are categorized based on theoretical proteins of its plant protein ingredients. These ingredients are those that showed to have at least 15% (db) declared protein by the ingredient suppliers.
• the working theoretical protein contents of DEBMs are the summations of the concentrations of protein sources.
• the referred plant protein sources may include the following ingredients in Table 2, but not limited to it, as the major protein source or its various combinations. Table 2. Plant protein sources and their theoretical protein contents
• carbohydrate ingredients Used in combination with protein ingredients are carbohydrate ingredients as secondary structure- forming ingredients of the DEBMs.
• Plant carbohydrate sources include, but not limited to, cassava starch, cornstarch, millet flour, quinoa flour, rice flour, rye flour, semolina flour, sorghum flour, tapioca starch, potato starch, and wheat flour.
• Table 3 shows the general categories of FFI, Philippines DEBMs using calculated theoretical protein contents as working criteria. The extruded products can still be further subcategorized into cut, granulation, shape, and color series per FFI, Philippines major extrudate categories.
• the dispersed phase filler ingredients of this invention are used to help create new extruded textured products with the brans and plant fibers contributing variably to length, diameter, radial expansion, porosity, bulk density, hydration yield, and fiber characteristics of the FFI, Philippines major extrudate categories.
• Brans include, but not limited to, oat bran, rice bran, wheat bran, white corn bran, and yellow corn bran.
• Plant fibers include, but not limited to, coconut meat fiber, oat fiber, potato fiber, and soya fiber.
• All extruded formulations are carried out in a twin screw extruder.
• the extruder has 5 temperature controls and processing temperatures are fixed at 30°C at Zone 1 and at 90°C for Zones 2 to 5.
• Screw speed is maintained at 1520 rpm and cutter speed at 315 rpm.
• Water input and feed rate are 55-75 kg/h and 115-145 kg/h, respectively.
• Table 4 presents the sample characteristics of bran from various plant sources that are incorporated in the examples of FFI extrudates with bran at 0.5% to 3.0% level of addition. Table 4. Characteristics of brans from different plant sources
• the following FFI, Philippines extrudates with brans and plant fibers of the invention are all referenced to the original basal formulations for DEBMs of FFI, Philippines without the prior incorporations of brans and plant fibers as dispersed phase fillers.
• the FFI-1 and FFI-2 without brans and plant fibers as dispersed phase fillers are high protein extrudates with more than 60% calculated theoretical protein (db) while FFI-3 and FFI-4 are intermediate products with theoretical protein 50 to 60% (db) of DEBM.
• Tables 5-6 the physical characteristics of the four major FFI, Philippines extruded products cited in this invention shown in Tables 5-6.
• the evaluated products of FFI-1 to FFI-4 are currently material which are commercially marketed as extruded nuggets with 40 to 60mm length and 45 to 50mm diameter.
• High protein extrudates, FFI-1 and FF-2 are significantly (p ⁇ 0.05) less expanded radially, have less percent area occupied by pores based in the cross section evaluation, and therefore, have greater percent apparent cell wall area than intermediate protein extruded products, FFI-3 and FFI-4.
• the high protein extrudates also have smaller pores than intermediate protein extrudates.
• FFI-2 is longest and least expanded radially among the FFI extruded products.
• the protein fibers of FFI-2 were noted to be softer and more elastic than the other high protein extrudate FFI-1. The difference in the type of protein sources in the various FFI, Philippines products determine the quality of protein fibers developed.
• Hydration ratio is the expression that quantifies the maximum hydration liquid that a dry extrudate can absorb or retain. Relative to the hydration yield, a part of the dry extrudate is subtracted from the computed yield that corresponds to the hydration liquid. Hydration yield was significantly (p ⁇ 0.05) highest in FFI-4, which is classified to contain least protein and highest carbohydrates based on DEBM declaration of percent sources of ingredients. Although FFI-1, FFI-2, FFI-3, and FFI-4 are four major base categories for FFI extrudates, range characteristics are nonetheless, still not too varied between FFI-1 and FFI-2 versus FFI-3 and FFI-4.
• the object of adding brans and plant fibers in this invention to the basal DEBM recipes of FFI, Philippines is to create more variations in physical characteristics of the extrudates, thereby, diversifying food applications.
• FFI-1 without bran is a high protein extrudate with > 60% calculated theoretical protein that exhibits a high fibrosity characteristic.
• the texturized product forms a plurality of fibers when hydrated and mechanical force is applied during shredding. Details regarding the effect of various bran incorporations in FFI-1 formulation in terms of length, diameter, radial expansion, porosity parameters, bulk density, hydration yield, and fiber characteristics are shown in Tables 7 to 9.
• brans may be within the structure of the cell wall of high protein extrudates with bran. Expansion may be attributed to cell wall thickening with ⁇ 1.0% bran incorporation.
• the addition of bran in FFI-1 is associated to the decrease in the number of pores and increase in pore sizes at lower bran concentrations. This is true at low levels of incorporation of 0.5 - 1.0% but not to 3.0% where radial expansion was significantly affected pore area and pore density. More porous product with thin cell walls is produced with 3.0% incorporation of bran wherein the pore size is significantly (p ⁇ 0.05) larger than the pore sizes of high protein extrudates without bran. It is shown that the highest radial expansion is best achieved by 0.5% rice bran incorporation than its oat and corn counterpart.
• the bulk densities of dried FFI-1 high protein extrudates with various bran applications are generally higher but not significantly different from the control. Although there is concomitant expansion at > 1.0% bran incorporation, bulk density is not affected due to weight of bran embedded in starch-protein matrix. There is significant decrease (p ⁇ 0.05) in the hydration yield when 0.5% oat bran and 0.5% rice bran are incorporated in FFI-1 extrudates in comparison with the control.
• the microscopic evaluation 200x magnification
• the fiber characteristics including: transparency; crimpling; and thickness, are described using a 100mm line scale with increasing change in fibers from 0 to 100%.
• the physical property of allowing transmission of light through the individual fiber is identified by four panelists as transparent (0%), translucent (50%), and opaque (100%) material. Crimpling, defined as presence of small irregular folds or ridges, of individual fiber is recognized as smooth (0%), separated waves (50%), and very wavy (100%). The dimension between the two surfaces of the individual fiber is rated as thin (0%), medium thickness (50%), and thick (100%) if height of material is ⁇ 0.15 mm, 0.20 - 0.35 mm, and > 0.40 mm, respectively.
• brans Concentration of brans variably affects the type of fiber developed. Thinner and smoother fibers are produced at higher bran incorporation (1.0% to 3.0%). Oat bran even at 0.5% level of addition results to increased opacity and thinning of individual fibers. Generally, addition of bran elongates the individual fibers probably due to the stretching of the melt as it encounters insoluble materials like bran. FFI-1 extruded products can still be further subcategorized into cut, granulation, shape, and color series as discussed below.
• FFI-1 uncolored flakes with bran The high protein FFI-1 extrudates from food grade biomaterials with incorporated brans up to 3.0% can be specifically classified as uncolored in color and flakes in form. These bran-containing extrudates can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods. High protein extrudate FFI-1 uncolored flakes are extruded using FFI-1 formulation with various bran incorporations that are subtracted from the percentage of carbohydrate sources in DEBM-1. The color of the finished product ranges from light beige (Pantone 468U) to beige (Pantone 7501U).
• FFI-1 uncolored extrudate can be mechanically cut by mill into dry food-like pieces of extrudates generally with a defined shape (round or square) and can be produced in varying thickness using grinder speed as controlling factor. These extrudates are dried to moisture content ⁇ 10% (db) using single-belt hot air dryer. The resultant flaked product of uncolored dry extruded material have hydration ratio of 1:4 extrudate to hydration liquid as compared to only 1:3 extrudate to hydration liquid when in nugget form. Milling would expose more surface area per unit weight of extrudate and therefore, more area available for water absorption.
• Tuna flakes in oil with 0.5% corn bran-containing FFI-1 uncolored dry flakes One test application of high protein extrudate FFI-1 with 0.5% corn bran as extender in processed or manufactured food is in tuna flakes in oil.
• the formulation for tuna flakes in oil with FFI-1 with 0.5% corn bran, uncolored dry flakes as shown in Table 10.
• Fish broth is prepared by boiling tuna bones and head to water at a ratio 1:2.
• the FFI-1 uncolored dry flakes are hydrated with previously prepared fish broth in a 1:4 extrudate to broth ratio.
• Tuna flakes and hydrated FFI-1 uncolored flakes are then lightly combined.
• Corn oil, salt and pepper are added. This mixture is canned as tuna flakes in oil using adequate heat treatment process for sterilization.
• the high protein FFI-1 extrudates from food grade biomaterials with incorporated brans up to 3.0% can be specifically classified as uncolored in color and shreds in form.
• bran-containing extrudates can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods.
• High protein extrudate FFI-1 uncolored shreds are extruded using FFI-1 formulation with various bran incorporations that are subtracted from the percentage of carbohydrate sources in DEBM-1.
• High protein FFI-1 extrudate with bran can also be mechanically cut by a mill into long meat-like dry strands which consist of multi-fibers or bundles of threadlike materials. These extrudates are dried to moisture content ⁇ 10% db using single-belt hot air dryer.
• the resultant product of uncolored dry shredded extruded material have hydration ratio of 1:4 extrudate to hydration liquid from 1:3 extrudate:hydration liquid when in nugget form. Increase surface area of cut materials also explains the increase in hydration yield.
• Chicken nuggets with 0.5% rice bran-containing FFI-1 uncolored dry shreds A test application of high protein extrudate FFI-1 with 0.5% rice bran dry shreds as extender in processed or manufactured food is in chicken nugget recipe.
• the formulation for chicken nuggets with FFI-1 uncolored dry shreds is shown in Table 11. Table 11.
• Frozen chicken meat and fat were partially thawed and chopped together in a bowl cutter. All other ingredients are chopped until cold emulsion is formed.
• the FFI-1 uncolored dry shreds were hydrated with chicken broth in a ratio of 1:4 extrudate to chicken broth.
• the tacky meat emulsion is then placed in a greased rectangular pan and stored in the freezer until firm for cutting.
• the frozen block of chicken emulsion with 0.5% rice bran-containing FFI-1 uncolored shreds was cut into desired sizes and shapes.
• Adequate amounts of flour, oil, eggs, and spices are used for pre-dusting, batter, and coating.
• the portioned meat pieces were pre-dusted with flour, battered in semi-liquid mixture of oil, eggs, and spices, and then coated with bread crumbs.
• the breaded pieces were fried in deep fat until golden brown or fully cooked with internal temperature of 70°C.
• the chicken nuggets can be stored at frozen conditions before complete frying prior to consumption.
• Example 2 Bran-containing FFI-3 intermediate protein extruded product
• FFI-3 without bran is an intermediate protein extruded product with 50 to 60% calculated theoretical protein (db).
• FFI-3 extrudates are expanded and porous, and are intended to be used generally to mimic minced pieces of meat once cut, milled, shredded or flaked. Details regarding the effect of various bran applications in FFI-1 formulation in terms of length, diameter, radial expansion, porosity parameters, bulk density, hydration yield, and fiber characteristics are shown in Tables 12 to 14. Table 12. Physical characteristics and porosity of FoodFlow, Inc. Formulation 3 (FFI-3) extrudates with 1.0% incorporation of various brans
• FFI-3 intermediate protein extrudates with 1.0% oat or corn bran significantly (p ⁇ 0.05) increased in bulk density that may be attributed to its decreased expansion.
• the inclusion of various brans to FFI-3 extrudates does not significantly change the hydration yield of dry extruded products.
• the fiber characteristics including: transparency; crimpling; and thickness, are described using a 100mm line scale with increasing change in fibers from 0 to 100%.
• the physical property of allowing transmission of light through the individual fiber is identified by four panelists as transparent (0%), translucent (50%), and opaque (100%) material.
• Crimpling defined as presence of small irregular folds or ridges, of individual fiber is recognized as smooth (0%), separated waves (50%), and very wavy (100%).
• the dimension between the two surfaces of the individual fiber is rated as thin (0%), medium thickness (50%), and thick (100%) if height of material is ⁇ 0.15 mm, 0.20 - 0.35 mm, and > 0.40 mm, respectively.
• FFI-3 uncolored flakes with bran The intermediate protein FFI-1 extrudates from food grade biomaterials with incorporated brans up to 3.0% can be specifically classified as uncolored in color and flakes in form. These bran-containing extrudates can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods.
• FFI-3 intermediate protein extrudate with bran can be mechanically flaked using a grinder with faster cutting speed to produce thinner and smaller flakes. These flaked extrudates are dried to moisture content ⁇ 10% (db) using single-belt hot air dryer.
• the resultant product of uncolored dry flakes extruded material have hydration ratio of 1:4 extrudate to hydration liquid from 1:3 extrudate:hydration liquid when prepared in nugget form. Flaking the extrudates provides greater surface area on final product and increases water absorption during hydration.
• Hotdog with 1.0% corn bran-containing FFI-3 uncolored dry flakes A test application of intermediate protein extrudate FFI-3 with 1.0% corn bran dry flakes as filler in processed or manufactured food is in hotdog recipe. In brief, the formulation for hotdog with FFI-3 uncolored dry flakes is shown in Table 15. Table 15. Hotdog Recipe
• the FFI-3 uncolored dry flakes with 1.0% com bran are hydrated with 4 parts water and are set aside. Beef and chicken meat are chopped at low speed using a bowl cutter. Then phosphate, salt, and a third ' of crushed ice are added with the meat mixture. The ingredients are chopped at low speed until tacky. Curing salt is added during chopping at low speed. Beef trimmings, protein, flavors, and another third of crushed ice are included in the blend followed by chopping at high speed. The previously hydrated FFI-3 uncolored grits are incorporated and chopped followed by the inclusion of starch and remaining crushed ice. The emulsion is chopped for about 2 minutes maintaining at ⁇ 12°C. The final emulsion is filled into 22 to 24 mm red cellulose casing and cooked until internal temperature of 75 to 80°C using a smokehouse (Bastra, Germany).
• FFI-3 colored granules with bran The intermediate protein FFI-1 extrudates from food grade biomaterials with incorporated brans up to 3.0% can be specifically classified as colored and granules in form. These bran-containing extrudates can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods.
• Intermediate protein extrudate FFI-3 colored are extruded using FFI-3 formulation with various bran incorporations and maximum of 5% incorporation of various combinations of food grade colorants such as FD &C dyes, pigments, and natural food colors utilized at their allowable limits. The amount of brans and colorants are subtracted from the percentage of carbohydrate sources in DEBM-3.
• the color of the finished product varies depending on the preferred shade of red, orange, and yellow.
• the example substitutions of extrudates for candied fruits are cherry pieces, pineapple, and orange peels.
• FFI-3 extrudate with bran can be granulated into small rectangular pieces using a die design customized for production of fruit and vegetable analog. These extrudates are dried to moisture content ⁇ 10% (db) using single-belt hot air dryer.
• the resultant product of colored extruded granules have hydration ratio of 1:2 extrudate to hydration liquid from 1:3 extrudate:hydration liquid when prepared in nugget form.
• the granules are smaller in size but have greater surface area covered by extrudate skin, thus, reducing the water absorption capacity of the extrudates.
• Fruit syrups of pineapple, cherry, and orange with 22 °Bx are prepared as steeping solutions for the colored extruded granules to be used as substitutes for fruits in the pudding recipe at 100% level of replacement.
• the flour and butter are placed in a mixing bowl and are rubbed together until mixed.
• the sugar, prepared extruded pieces soaked in fruit syrup, egg, and milk were added and mixed until thoroughly blended.
• the pudding basin is greased, the combination of orange marmalade and pineapple jam is placed in the bottom of the basin, and the mixed batter is added.
• the top of the basin is loosely covered with foil and steamed for 1 hour and 30 minutes.
• the pudding can be served with the remaining fruit sauce used for soaking the extrudates.
• FFI-3 extrudate with 1.0% rice bran and about 5% blend of food grade colorants to obtain different shades of green are granulated into small rectangular granules using a die design to produce pieces of vegetable analogs such as leeks, cabbage, lettuce, asparagus, and coriander. The cutter speed is varied according to the desired profile of vegetable analog.
• FFI-3 extrudate with bran and about 5% blend of food grade colorants to obtain bright shade of orange can also be granulated into small square pieces to be applied as analog for diced carrots.
• blend of food grade colorants to obtain brown shade may be done to produce analog for ground beef. The total amount of various combinations of colorants is subtracted from the percent of carbohydrate sources in DEB -3 of FFI-3 formulation.
• extrudates are dried to moisture content ⁇ 10% (db) using single- belt hot air dryer.
• the resultant product of colored extrudate granules have hydration ratio of 1:2 extrudate to hydration liquid from 1:3 extrudate:hydration liquid when prepared in nugget form.
• Spice mix was packed separately in a sachet.
• FFI-3 with 1.0% rice bran, dry colored (orange, brown, and green) extruded granules were packed together in a sachet as toppings.
• the sachet for spice mix and toppings were packed together with dried instant noodles in its primary packaging material.
• FFI-3 extrudate with 1.0% corn bran is incorporated with about 5% blend of food grade colorants to match cooked pork-like color. The amount of bran and colorants are subtracted from the percent of carbohydrate sources in DEBM-3 of FFI-3 formulation. These extrudates are dried to moisture content ⁇ 10% (db) using single-belt hot air dryer.
• the resultant product of colored pieces of extruded material have hydration ratio of 1:2 extrudate to hydration liquid from 1:3 extrudate:hydration liquid when prepared in nugget form.
• the granules are smaller in size but have greater surface area covered by skin, thus, reducing the water absorption capacity of the extrudates.
• Meat Portions 20.00 Cooked ground pork meat 5.00 FFI-3 brown dry granules with 1.0% corn bran 5.00 Pork broth for FFI-3* 10.00
• FFI-3 brown dry granules with 1.0% corn bran are hydrated using 1:2 extrudate:pork broth.
• Ground meat and hydrated FFI-3 brown dry granules are stir fried in oil and added with onions, pepper, soy sauce, and sugar.
• Vegetable portions, except bean sprouts, are also stir fried until the vegetables softened. Mixed meat and vegetable portions are removed from heat. Bean sprouts are then tossed in the mixture.
• Ample amounts of stir-fried mixture are wrapped in thawed spring roll wrappers. Wrapped spring rolls are deep fat fried and served with sweet chili sauce.
• FFI extrudates can be manufactured utilizing plant fibers in replacement for brans. FFI extrudates with plant fiber incorporation at 0.5 to 3.0% to produce products that are quite dense and not too expanded.
• the different plant fibers that can be substituted to bran, but not limited to it, are: bamboo fiber, coconut meat fiber, oat fiber, potato fiber, and soya fiber.
• incorporation of plant fibers is expected to possess the following characteristics as compared with its corresponding control: longer extrudates, less expansion, more number of pores, smaller pore sizes, and increase in apparent cell wall area. Even if the protein is already considered intermediate, the incorporation of fibers improves the texture of extrudate by increasing its density and providing stronger cell wall to surround its pores.
• the high protein and intermediate protein extrudates from food grade biomaterials with incorporated plant fibers up to 3.0% can be subcategorized into colors, forms, cuts, shapes, and granulations, and can be applied as extender, filler, and analog of meat, vegetable, fruit, fish and fishery recipes and products in food service-prepared, processed, or manufactured foods.

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