EP4266897A1 - Produit à base de protéines, élastique, présentant une structure de type mousse, procédé de production de produits de ce type, en particulier de simili-carnés extrudés à base de fibres végétales et de protéines végétales, dispositif pour mettre en ?uvre un tel procédé et utilisation du produit pour produire des simili-carnés à base de protéines végétales - Google Patents

Produit à base de protéines, élastique, présentant une structure de type mousse, procédé de production de produits de ce type, en particulier de simili-carnés extrudés à base de fibres végétales et de protéines végétales, dispositif pour mettre en ?uvre un tel procédé et utilisation du produit pour produire des simili-carnés à base de protéines végétales

Info

Publication number
EP4266897A1
EP4266897A1 EP21824478.8A EP21824478A EP4266897A1 EP 4266897 A1 EP4266897 A1 EP 4266897A1 EP 21824478 A EP21824478 A EP 21824478A EP 4266897 A1 EP4266897 A1 EP 4266897A1
Authority
EP
European Patent Office
Prior art keywords
product
nozzle
opening
slot
extruder
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.)
Pending
Application number
EP21824478.8A
Other languages
German (de)
English (en)
Inventor
Erich Windhab
Joel Zink
Cédric SAX
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Eidgenoessische Technische Hochschule Zurich ETHZ
Original Assignee
Eidgenoessische Technische Hochschule Zurich ETHZ
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from DE102020007892.3A external-priority patent/DE102020007892A1/de
Application filed by Eidgenoessische Technische Hochschule Zurich ETHZ filed Critical Eidgenoessische Technische Hochschule Zurich ETHZ
Publication of EP4266897A1 publication Critical patent/EP4266897A1/fr
Pending legal-status Critical Current

Links

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
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • A23J3/225—Texturised simulated foods with high protein content
    • 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
    • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
    • A23J3/00—Working-up of proteins for foodstuffs
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • 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
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • A23J3/225—Texturised simulated foods with high protein content
    • A23J3/227—Meat-like textured foods
    • 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
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • A23J3/24—Working-up of proteins for foodstuffs by texturising using freezing
    • 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
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • A23J3/26—Working-up of proteins for foodstuffs by texturising using extrusion or expansion
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/30—Puffing or expanding
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/40—Foaming or whipping
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2300/00—Processes
    • A23V2300/10—Drying, dehydrating
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2300/00—Processes
    • A23V2300/16—Extrusion
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2300/00—Processes
    • A23V2300/31—Mechanical treatment

Definitions

  • the invention relates to a foamed, elastic, protein-based product.
  • the invention relates to a method for producing such a product with a defined degree of pore opening.
  • the invention also relates to a device for carrying out the method according to the invention.
  • the invention relates to the use of the product according to the invention as the main component for producing meat analogs based on plant proteins.
  • Viscous masses can be foamed in extruders, in which gas is metered in under atmospheric or excess pressure, mixed/dispersed and/or partially or completely dissolved under excess pressure, is then released again by pressure relief and remains partially or completely incorporated in the viscous mass to form a foam /1,2 /.
  • foaming agents which form a gas as a result of a chemical/physicochemical and/or thermal reaction, which is also partly or completely incorporated into the viscous mass with the aid of mixing/dispersing processes to form a foam.
  • Corresponding viscous masses can be of a synthetic and/or biological nature or also consist of mixtures of such and can be the basis or component of products in the food, cosmetics, pharmaceuticals, building materials or plastics industries.
  • viscous masses foamed in this way are conveyed by the extruder screws and pressed through an extruder die.
  • the aim is for a material strand with a defined shape to emerge from the extruder nozzle, since the product is also typically shaped by means of the extruder nozzle.
  • the dimensional accuracy of such products is often also an important quality measure. This is achieved, among other things, by realizing a uniform laminar flow in the nozzle, which corresponds to a planar layered flow. If a foamed fluid system is moved in such a nozzle flow, there is increased shearing of the fluid system at the nozzle wall due to the typical parabolic flow profile, whereas no shearing occurs in the middle of the nozzle channel. Cross-mixing of the fluid system flowing in this way does not occur (parallel layered flow) provided the nozzle channel does not have any flow obstacles.
  • the maximum wall shear rate present in the fluid layer in contact with the wall usually causes the formation of a boundary layer close to the wall. If the fluid system contains disperse components, these are set in rotation as a result of the wall shear rate effective in the fluid layer close to the wall under consideration and experience a dynamic buoyancy force (lift force), which causes the disperse components to separate away from the wall in the center of the nozzle channel. This applies in principle to solid particles /3/ but also to gas bubbles /4/ and leads to a depletion of the fluid layer close to the wall of such disperse components.
  • HMEC High Moisture Extrusion Cooking
  • HMEC High Moisture Extrusion Cooking
  • protein denaturation takes place in the form of protein fibrils that form, which are oriented in the direction of flow in the extruder nozzle inlet flow as a result of stretching flow components that are effective there and as a result of subsequent cooling (to approx. 60°C) in a long (> approx. 1 m) extruder cooling nozzle in this oriented structural state.
  • the cooled product emerges from the extruder nozzle as a smooth strand with typically laminar nozzle flow.
  • the oriented protein fibrils give the product a meaty fibrous texture /5/ As a result of the slow cooling of the product in d
  • the extruder nozzle suppresses a sudden release of water vapor and thus does not disturb the formation of the structure.
  • US20050003071 A1, WO2016150834 A1 and US 10,716,319 B2 are comprehensively described.
  • US 10,716,319 B2 (Method of making a structured protein composition) is considered from a technological point of view as the closest description (closest state of the art) to the technology according to the invention described in this patent application: (Translated abstract from US 10,716,319 B2): “The fibrous composition obtained in the extruder leaves the extruder at a temperature of the composition that is higher than the applicable boiling point of water (e.g. 100 °C at atmospheric pressure or lower if one vacuum port is used). It is believed that this leads to expansion and subsequent collapse of the textured product.
  • the applicable boiling point of water e.g. 100 °C at atmospheric pressure or lower if one vacuum port is used
  • the extrudate according to the invention is infused into the moist product obtained by extrusion.
  • the extrudate of the present invention does not require drying and rehydration. It remains substantially moist and is then further filled with water or other aqueous composition by infusion.
  • the extrudate preferably has a water content of from 55% to 70% by weight.
  • the structured vegetable protein composition resulting from infusion with an aqueous liquid preferably has a water content of from 70% to 90% by weight.
  • the above-mentioned infusion can be enhanced (ie drain more quickly and/or allow more water to be incorporated) by an aqueous liquid if the extrudate has been frozen first (and then thawed prior to infusion).
  • the freezing temperature is below -5°C and -15°C.”
  • microfoaming of highly viscous and viscoelastic, dough-like, protein and non-protein-based masses by means of extrusion processes is described in WO 2017/081271 A1.
  • a foamed product can also lead to a product with a better controlled foam structure by means of gas metering and gas dispersion or gas dissolution and renucleation of gas bubbles.
  • gas metering and gas dispersion or gas dissolution and renucleation of gas bubbles typically have closed pores and, as they flow through the extruder die, form a skin layer largely free of foam bubbles and pores as a result of the maximum shear near the wall.
  • the invention is initially based on the object of producing a foamed product with a high bound water content, in the case of extruded meat analogy based on a concentrated vegetable protein melt with > 30% by weight vegetable protein content and > 5% by weight vegetable fiber content and a gas volume content in the end product of > 10 vol. % to create, whereby the gas volume is in the form of pores/bubbles, which should be present in an adjustable proportion as pores open to the product surface, e.g. in order to accelerate further liquid absorption, with sensory and/or nutritionally relevant components contained in this liquid in the to ensure product.
  • the new, foamed products according to the invention allow, via the setting of the foam pore opening degree, a coupled setting of certain sensory and nutritional attributes as "intrinsic" properties of these products, which have not been possible for conventional products of this category or only to a small extent through additional products (sauces, toppings, etc.). ) could be achieved.
  • the (a) sensory quality attributes that are relevant for the consumer: tenderness, juiciness, crispiness, meat taste/aroma (b) nutritional functionalities (e.g. through the introduction of bioavailable iron and B -Vitamins) and (c) convenience properties by enabling or improving the ability to cook, roast and grill, made available in a way that can be adjusted.
  • a closed foam pore structure enhances the sensory texture impressions of (i) tenderness but also (ii) gumminess in the case of solid structures of the Foam lamellae surrounding gas bubbles and (iii) creaminess (creaminess) in the case of fluid foam lamellae properties.
  • Open-pored, spongy foam structures allow the sensory textural attributes (iv) crunchyness but also (v) brittleness to come to the fore with firm foam lamellar properties.
  • the case of fluid foam lamellar properties is irrelevant for open-pored product systems, since deliquescence of the matrix material leads to a foam with closed pores.
  • foamed meat analog products with at least partially open pores
  • their sensory, nutritional and preparation convenience properties can be significantly expanded in that the pores of the foamed base product are partially or completely filled with functional or functionalized fluids, such fluids after pore filling can also solidify.
  • functional or functionalized fluids such fluids after pore filling can also solidify.
  • the subject of the invention is based on a HMEC technology as described above for the preferred production of plant protein-based meat analogues, with this technology being significantly supplemented by a combination with a micro-foaming process, which takes place in the extruder and in a comparable manner, based on the production of foamed baked goods was described in 121.
  • a defined amount of gas e.g. N2, CO2
  • N2, CO2 is first dissolved in the aqueous protein melt in the extruder under the high pressure set there and then released again by reducing the pressure in the extruder cooling nozzle. Gas bubbles are nucleated at the beginning of the extruder nozzle and enlarged as the nozzle flow progresses with progressive pressure release, thus forming a foam structure.
  • the (i) high shear of the cooling, foamed protein melt in the vicinity of the nozzle wall supports in addition to the named effect of (ii) improved gas solubility, a (iii) reduction in gas bubbles due to flow effects (dynamic buoyancy forces) in the nozzle wall zone.
  • the "skin layer" of the extruded, foamed meat-analog strand which is partially or completely depleted of gas bubbles, shields inner foam pores from the environment.
  • a product skin layer formed as described remains closed. For the micro-foamed products this means the presence of a closed foam pore system.
  • the subject of the invention addresses a technology for adjusting the ratio of closed pores/bubbles to open pores/pore channels that are open towards the product surface. In principle, this can also be achieved mechanically by connecting originally closed foam bubbles/pores, provided that these can be brought to coalescence or the formation of connecting channels between them and to the product surface in a defined manner, without significant loss of the total gas volume fraction and fine pores.
  • the characteristics of the pore channels formed in the direction of pressure release and their opening outwards towards the surface of the extruded strand is decisively determined by the rheological properties of the extruded product at the time it emerges from the extruder die. Lower viscosity (or elasticity) allows more pronounced material deformation under the effect of the relaxation pressure gradient and, as a result, more pronounced pore channel formation.
  • the embodiment of the geometry of the adjustable slot nozzle device (VSDA) according to the invention enables a different geometric shaping of the course of the flow cross section in the direction of flow.
  • the constriction is preferably abrupt (approx. 90°), which forces the formation of a secondary flow of the extrusion strand fluid in the zone of the widening again of the flow channel cross section.
  • the static pressure is significantly lowered and, on the other hand, a roller-like secondary flow is generated, which causes the strand fluid to be mixed transversely to its direction of flow in the vertical direction of the slot nozzle channel.
  • the "inside-out turn" of the extrusion strand material depends on the intensity of the secondary därstrom and their rotation frequency.
  • Claim 2 describes a product in which the protein content is 10-95% by weight in its dry substance
  • claim 3 describes a product in which the protein content is 0-100% by weight of vegetable protein.
  • the product in claim 4 is characterized in that the protein in the product is in partially to fully denatured form and has a fibrillar structure, while the product according to claim 5 is characterized in that the denatured form has an oriented fibrillar structure.
  • Claims 6 to 8 take into account ingredients and their quantities which are of particular importance for the setting of the sensory and nutritional corresponding vegan meat analogues.
  • the product according to claim 6 contains a plant fiber content of 0.5 - 20
  • a product is described in which the product contains a proportion of fats or oils of 0.1 - 15% by weight, based on the dry substance, while the product in claim 8 is characterized in that it contains a proportion of flavoring and /or coloring and/or components that increase the nutritional value in addition to the plant fiber content of 0.1 - 5% by weight, based on the dry substance.
  • claim 9 proposes a product which, after drying to a residual water content of ⁇ 5% by weight and spoilage-free, moisture-controlled storage for several months under room temperature conditions, when brought into contact with water or a water-containing fluid system, is restored to its original volume and texture, without loss of dry substance .
  • Claim 10 describes a product which, after drying to a residual water content of ⁇ 5% by weight and spoilage-free, moisture-controlled storage for several months under room temperature conditions, is reconstituted when it comes into contact with water or a water-containing fluid system, restoring its original volume and texture.
  • COP opening by multiple needle penetration (penetration-opening, POP), (d) opening by forced secondary mixed flow (mix-opening, MOP), and (e) opening by freeze-patterning (freeze-opening, FOP) individually or be applied in coupling, whereby the opening of gas pores trapped in the foamed product or
  • the method according to the invention and its configurations can be coupled directly to the HM EC extrusion process and the extrusion parameters to be set for structuring the protein matrix for the pore opening can be directly transferred.
  • the static pressure built up in the extruder can be maintained up to the end of the die to such an extent that a sufficiently rapid and efficient residual pressure relaxation can be realized at the pore opening.
  • part of the kinetic flow energy of the extrudate strand is used to generate a cylindrical secondary flow that also periodically oscillates for viscoelastic masses, which is transverse to the flow in the vertical direction of the extruder Slot nozzle causes a thorough mixing, which elongates closed foam pores, moves them towards the surface of the strand and "tears open” the surface structure in such a way that the intensity can be adjusted, so that a part of the correspondingly treated pores, which can also be adjusted, is opened towards the product surface.
  • MOP forced secondary mixed flow
  • the adjustability of the degree of pore opening is based on the adjustability of the intensity of the mixed secondary flow, which in turn can be adjusted within wide limits by adjusting a local slot nozzle height reduction and the transport speed of the extrudate strand (e) for pore opening by freeze structuring is used according to the invention on foam structures in order to penetrate primarily large ice crystals for penetrating material partitions between closed pores at a preferably slow freezing rate and thus convert them into open pores.
  • the high water content (up to 60% by weight) of the plant protein-based meat analogues considered as preferred helps to support the formation of ice crystals.
  • the pore-opening processes are detailed in their technical implementation by means of mechanisms (a)-(e), (a) mobilizes compressive forces to break open pore boundaries outwards towards the product surface. (b) uses targeted incisions to expose the pore openings, (c) creates connecting channels between the closed product pores and outwards to the product surface through needle penetration, (d) refers to the generation of secondary flows in the extruder cooling nozzle in order to create largely closed flows in the laminar slot nozzle flow Breaking up product skin layers by cross-mixing in the height coordinate direction of the nozzle channel and creating additional superficial transverse channels/channels.
  • an additional flow-dynamic feature of viscoelastic fluid systems can be advantageously used according to the invention.
  • the so-called elastic turbulence effect arises as a result of the elastic deformation energy storage in the converging inlet flow of a slot nozzle aperture (VSDA) designed according to the invention and arranged in a defined manner in the nozzle channel and adjustable with regard to slot channel constriction.
  • VSDA slot nozzle aperture
  • variable slot die aperture (VSDA) device according to the invention is installed in the extruder cooling die, typically in the first two thirds of its length. In this way, the elastically-turbulently mixed product strand is partially evened out again in a defined manner in the laminar layer flow that is restored after the aperture and crack formations in the structure are gradually healed again, if desired.
  • the degree of OSMS adjustable via the VSDA as described and the length of the extruder nozzle in the aperture wake are matched according to the invention or calibrated specifically for the material system.
  • Claims 22 and 23 refer to the possibility of drying the products after the pore opening has taken place according to one or a combination of methods (a)-(e) in order thereby to achieve an extended shelf life at ambient temperature storage.
  • the opening of the pores advantageously accelerates the transport of water during drying and also during reconstitution.
  • patent claims 24 and 25 the basic conditions for the accuracy of setting the degree of pore opening and the underlying total gas pore volume in the product, which should have or should have an open connection to the product surface, are specified.
  • the resulting bandwidth from (i) a minimum of 10% by volume total gas content (in pore form) with 5% open to (ii) a maximum of 80% by volume total gas content (in pore form) with 90% open is relevant for foamed meat analogues, for example in case (i), for example, to achieve easy penetration with intensively flavoring substances in fluid form, and in case (ii), for example, to homogeneously penetrate 72% of the product volume with a fluid phase that gives consistency/texture and that may solidify after pore filling.
  • application to meat analogues resulted in a scaffolding protein structure with, for example, a vegan pie/sausage filling.
  • "marbled" product structures with an adapted fat/gel insert can be realized in order to further adjust typical meat/fat/connective tissue/gel structures and associated sensory preferred texture properties.
  • the gas-filled volume fraction is limited to 80% by volume, since the pore opening mechanisms according to the invention, which are related to rather solid foam products, can no longer be transferred sufficiently non-destructively to the overall product if the foams are too fragile.
  • the pore opening mechanisms use mechanical, fluid mechanical or thermodynamic principles to open closed pores to the product surface by means of a:
  • the core element of the devices for activating the pore opening mechanisms according to (a) and (d) is a variable slot nozzle aperture (VSDA).
  • VSDA variable slot nozzle aperture
  • Their free cross-sectional area for the passage of the extrudate corresponds exactly to the dimensions of the free cross-section of the extruder slot nozzle when it is 100% open.
  • a cut, rotatably slide-mounted metal cylinder (2) is embedded in the aperture housing (1) in a sealing manner in the upper and lower walls delimiting the flow slot of the aperture device over the entire slot width, perpendicular to the direction of flow. When the aperture is fully open, the gate surfaces of these cylinders are flush with the flow channel wall (3).
  • the metal cylinders (2) can be rotated manually or by means of two servomotors in a controlled or regulated manner so that the aperture narrows on one side or is symmetrical to the longitudinal axis of the nozzle, which at a twist angle of 90° corresponds to the maximum
  • the degree of closure of the slit channel cross section corresponds to (further details, see description of the figures, FIG. 1).
  • Activation of the pore-opening mechanism d) to generate a secondary mixed flow (mix-opening, MOP) in the extruder cooling nozzle can take place solely by means of the VDSA device. In case (d), this is integrated into the nozzle at a position between 10-95% of the nozzle length measured from the nozzle exit end. In the case of a severely disintegrated extrudate structure, this ensures that this reintegrates to a part on the remaining stretch of the die after the passage through the aperture, thus preventing the extrudate strand from disintegrating at the die outlet.
  • the VDSA device is integrated into the nozzle in a position between 0-10% of the nozzle length measured from the nozzle outlet end. This ensures that the abrupt relaxation of the static residual pressure and thus the opening of the pores towards the extrudate surface only takes place shortly before the nozzle exit or directly at the nozzle exit.
  • extrudate is additionally suddenly subjected to a partial vacuum to open the pores, cut off extrudate parts are post-treated in a separate, quasi-continuously operating vacuum device directly after the nozzle outlet.
  • This additional treatment variant is preferably used for softer extrudates which, in the case of protein-based meat analogs, have a higher die outlet temperature or a higher water content.
  • a cutting/paring knife arrangement is arranged shortly before the exit or directly at the exit of the extrudate strand from the extruder nozzle.
  • the extrudate strand feed is thus used to implement the cutting forces.
  • Internal foam pores are thus opened towards the newly created product surface. This is indicated in particular when a "skin layer" with fewer foam pores has formed in the nozzle flow.
  • the opening of the pores can be carried out effectively and reproducibly by means of the devices configured according to the invention, the quality and degree of the opening of the pores still being determined by the material behavior of the extrudate. This must have a basic strength or yield point which ensures that the open pores produced are not closed again by the matrix mass flowing together. Due to the fact that the pore opening mechanisms (a)-(e) can be superimposed, which is advantageous in accordance with the invention, and the devices according to the invention provided for this purpose, a sufficient pore opening efficiency can also be ensured for critical, soft extrudates.
  • FIG. 1 shows the variable slot nozzle aperture (VSDA) according to the invention for a flat slot nozzle.
  • VSDA variable slot nozzle aperture
  • 1 aperture housing
  • 2 truncated rotatable, slide-mounted metal cylinder - 2a in O-position with free flow cross-section
  • 1 b turned clockwise
  • 2c turned counter-clockwise
  • 3 slot nozzle wall
  • 4a - 4c Aperture inlet flow for the differently rotated metal cylinder settings according to 2a-2c
  • 5a - 5c aperture outlet flow for the differently rotated metal cylinder settings according to 2a-2c
  • 6 geometric designations for positioning the metal cylinders
  • a angle of rotation of the metal cylinders
  • ß angle between metal cylinder center and edges of the gate surface of the metal cylinder.
  • a cut, rotatably slide-mounted metal cylinder (2) seals into the aperture housing (1), but is rotatable admitted.
  • the gate surfaces of these cylinders are flush with the flow channel wall (3).
  • the metal cylinders (2) can be rotated by hand or by means of two servomotors, so that the aperture narrows on one side or symmetrically to the longitudinal axis of the nozzle, which corresponds to the maximum degree of closure of the slot channel cross-section at a twist angle of 90° .
  • the mechanism for adjusting the height of the slot gap is implemented via a concentric, conical design of the inner wall of the die housing and an axially displaceable stamp with a conical tip, as shown in FIG.
  • the device according to the invention as shown in FIG. 3 is used for the additional post-treatment according to the application of the pore opening mechanism (a) for pore opening by means of a rapid drop in ambient pressure (flash opening, FOP) by means of partial vacuum application.
  • the pore opening mechanism (a) for pore opening by means of a rapid drop in ambient pressure (flash opening, FOP) by means of partial vacuum application is used for the additional post-treatment according to the application of the pore opening mechanism (a) for pore opening by means of a rapid drop in ambient pressure (flash opening, FOP) by means of partial vacuum application.
  • POT3 The device for realizing the pore opening according to mechanism (c) for multiple needle penetration (Penetration-Opening, POP) is arranged directly after the extruder nozzle exit and combines in the preferred embodiment of the device according to the invention two counter-rotating hollow needle or barb felt needle rollers, where the needles penetrating the extrudate from both sides intermesh as shown in FIG.
  • POT-4 The device for realizing the pore opening according to mechanism d) for generating a secondary mixed flow (Mix-Opening, MOP) in the extruder cooling nozzle can in principle be limited to the Adjustable Slot Nozzle Aperture (VSDA) device, for in -line control of the intensity of the set secondary mixed flow, however, the coupling with a measuring arrangement according to the invention for determining the static pressure before and after the VSDA device is indicated. This pressure measurement arrangement is shown in combination with the VDSA device in FIGS.
  • MOP Magnetic-Opening
  • FIG. 7 contains an expansion of the pressure measurement arrangement from FIG. 6 for the case of viscoelastic fluids, as are present in the case of protein melts for the production of meat analogues.
  • the aforementioned VSDA is installed according to the invention at a greater distance from the die outlet in the extruder die than in the POT-1 technology.
  • the aforementioned secondary flows as a result of adjustable channel cross-section narrowing and widening are significantly forced by the effect of elastic turbulence (relaxation of the elastic extra-normal stresses and the resulting reverse deformation of the strand). This effect can be triggered even with a slight narrowing of the slot nozzle cross-section and its expression can be set and used in a targeted manner to create an open pore structure.
  • static pressure measurements are carried out at a position in the extruder housing in front of the nozzle inlet cross section (P1) at two longitudinal positions in the extruder slot nozzle (P2, P3) after the nozzle inlet zone (after the conical narrowing), after the VSDA (P4), and (P5) in the slot nozzle channel in front of the VSDA, directly opposite (slot nozzle channel underside) to the pressure measurement position P2.
  • the arrangement according to the invention of the pressure measurement points P1-P3 and P4 means that there are separate rheological parameters for (a) the shear viscosity, (b) the elongational viscosity and (c) the elasticity of the extruded mass under the given extrusion conditions.
  • the VSDA device is adjusted with regard to the slot nozzle height reduction in such a way that the intended degree of secondary mixed flow with a correlated pore opening effect results.
  • a quantitative criterion for setting the VSDA slot opening to trigger or set a gradual expression of the forced "elastic-turbulent secondary flow mixing effect" can be determined, which leads to the pore opening according to the invention using the POT-4 technology and the thus triggered Mechanism (d) enabled in an adjustable manner.
  • LD nozzle length
  • the extrudate strand in the event of partial disintegration in the undisturbed nozzle flow, "heals” again after passing through the VSDA to such an extent that a compact, cohesive, foamed, partially open-pored product strand results without the through repeated flow-related "skin formation". destroying the pore opening effect achieved by elastic-turbulent mixing.
  • FIGS. 8-10 Exemplary representations of plant protein-based meat analog product structures and degrees of pore opening according to the invention achieved with the devices according to the invention using the method according to the invention are described below in FIGS. 8-10.
  • Material/basic recipe 52.5% water, 0.5% oil, 41.2% pea protein isolate (PPI), pea fiber 5.8% Process conditions: screw speed: 230 rpm; mass flow 37.5 kg/h; Nozzle entry temperature of the melt: 150° C.; Extruder outlet pressure: 18 - 20bar, nozzle cooling temperature: 60°C
  • Example 1 Pore opening mechanism by means of (a) sudden residual pressure relaxation and (d) superimposed forced secondary mixed flow.
  • the degree of pore opening (POG) was determined according to:
  • the surface of the extrudate shows increasing “fissures” as the height of the VSDA slot die channel increases, as a result of the imposed forced secondary mixed flow with simultaneous residual pressure relaxation. This is a typical image of the resulting product when installing the VSDA at the nozzle end.
  • Example 2 Pore opening mechanism by means of (d) forced secondary mixed flow, generated by means of an adjustable slot nozzle aperture (VSDA) installed with a nozzle length of 0.75 m from the nozzle outlet when the slot channel height reduction is set DH / % ⁇ 15%.
  • VSDA adjustable slot nozzle aperture
  • Example 3 pore opening mechanism by means of (d) forced secondary mixing flows. generated by means of an adjustable slot nozzle aperture (VSDA) installed with a nozzle length of 0.3 m from the nozzle outlet when the slot channel is set to a height reduction DH / % ⁇ 15%.
  • VSDA adjustable slot nozzle aperture
  • FIG 11 shows an enlarged image of the product surface.
  • the wavy stripe pattern structures are clearly visible.
  • (H) lighter (more foamed) and (D) darker (less foamed) areas alternate in strips.
  • the H areas originate from the inner strand foam structure, which is conveyed to the product surface by the forced secondary mixed flow.
  • the D-areas originate from the original "surface-
  • Example 4 (see FIG. 12): pore opening by means of (b) cutting/peeling mechanism produced by means of an adjustable cutting device installed at the nozzle outlet end.
  • Figure 12 shows a foamed, continuously cut strand of extrudate. Open pore structures can be detected on the cut surface. A pore opening degree of approx. 10-15% was achieved in the example shown. The extrudates on which this example is based had about 15-20% gas by volume.
  • a total volume of open pores of 2-5% is rated as sufficient for enriching the plant protein-based meat analogues described as an example with sensory (aroma, taste) and nutritional (B vitamins, minerals (Fe, Zn)).
  • sensory as an example with sensory (aroma, taste) and nutritional (B vitamins, minerals (Fe, Zn)).
  • B vitamins, minerals Fe, Zn
  • > 10% is relevant, depending on the water content of the product matrix.
  • Gap adjustment punch axial
  • Adjustment plunger guide tube 0 Tempering fluid inlet Tempering fluid outlet Tempering fluid channels a Tempering fluid ducts, inner b Tempering fluid ducts, outer c Tempering fluid ducts in the adjustment stamp Guides Nozzle gap a Nozzle gap in initial position b Narrowed gap setting through the nozzle gap Ring slot nozzles Flange Slot nozzle flow channel Laminar slot nozzle flow Cutting device Extrudate strand a Needle roller, upper b Needle roller, lower Penetration needle conveyor belt dividing device a penetration needle roller pressure dividing device, upperb penetration needle roller pressure dividing device, lower conveyor belt, partially perforated a vacuum half-shell, upper b vacuum half-shell, lower a contact pressure pneumatics, upper b contact pressure pneumatics, lower extrudate part, cut off a Piping for exhaust b Piping for exhaust Partial vacuum storage tank Vacuum pump String cutter Diaphragm pressure transducer 37 diaphragm pressure transducer
  • Diaphragm pressure transducer a Angle of rotation of the metal cylinder 2 ß Angle between the center of the metal cylinder and the edges of the cut surface of the
  • metal cylinder 2 ö angle of rotation of metal cylinder 2
  • Patent Foamed dough-based food product and apparatus and method for making the foamed dough-based food product; Patent Application No. DE 10 2016 111 518 A1

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  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Nutrition Science (AREA)
  • Biochemistry (AREA)
  • Molecular Biology (AREA)
  • Manufacturing & Machinery (AREA)
  • Formation And Processing Of Food Products (AREA)
  • Meat, Egg Or Seafood Products (AREA)

Abstract

L'invention concerne un produit ayant une structure de type mousse présentant un rapport défini des pores de gaz ouverts en direction de la surface du produit aux pores de gaz fermés. Cette invention concerne également un procédé mis en œuvre selon quatre modes de réalisation de l'invention pour l'ouverture mécanique définie de pores de mousse fermés. L'invention concerne également un dispositif mis en œuvre selon quatre modes de réalisation de l'invention pour l'ouverture mécanique définie de pores de mousse fermés. L'invention concerne également l'utilisation de produits conçus selon l'invention en tant que simili-carnés ou aliments à phases multiples texturés à base de protéines végétales, plus particulièrement des composites de légumes ou de fruits. Les avantages spécifiques de l'invention résident dans l'influence ciblée sur les propriétés de déformation et de texture des produits présentant une structure de type mousse et leur accessibilité depuis l'extérieur pour un remplissage rapide et facile des pores ouverts avec des systèmes fluidiques qui introduisent des fonctionnalités supplémentaires dans le produit.
EP21824478.8A 2020-12-23 2021-12-06 Produit à base de protéines, élastique, présentant une structure de type mousse, procédé de production de produits de ce type, en particulier de simili-carnés extrudés à base de fibres végétales et de protéines végétales, dispositif pour mettre en ?uvre un tel procédé et utilisation du produit pour produire des simili-carnés à base de protéines végétales Pending EP4266897A1 (fr)

Applications Claiming Priority (3)

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DE102020007887 2020-12-23
DE102020007892.3A DE102020007892A1 (de) 2020-12-23 2020-12-24 Geschäumtes, elastisches, protein-basiertes Produkt, Verfahren zur Herstellung solcher Produkte, insbesondere von pflanzenprotein- und pflanzenfaser-basierten extrudierten Fleischanalogen, Vorrichtung zur Durchführung eines solchen Verfahrens sowie Verwendung des Produktes zur Herstellung von pflanzenprotein-basierten Fleischanalogen
PCT/EP2021/000153 WO2022135732A1 (fr) 2020-12-23 2021-12-06 Produit à base de protéines, élastique, présentant une structure de type mousse, procédé de production de produits de ce type, en particulier de simili-carnés extrudés à base de fibres végétales et de protéines végétales, dispositif pour mettre en œuvre un tel procédé et utilisation du produit pour produire des simili-carnés à base de protéines végétales

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DE102023106026A1 (de) * 2023-03-10 2024-09-12 Nexnoa Gmbh Verfahren zum erzeugen eines texturats und extruderanordnung
DE102023106032A1 (de) * 2023-03-10 2024-09-12 Nexnoa Gmbh Verfahren zum erzeugen eines texturats und extruderanordnung
WO2024188907A1 (fr) * 2023-03-10 2024-09-19 Nexnoa Gmbh Procédé de production d'un texturat et texturat contenant des protéines

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AUPQ044099A0 (en) 1999-05-18 1999-06-10 Effem Foods Pty Ltd Method and apparatus for the manufacture of meat analogues
US7070827B2 (en) 2003-07-03 2006-07-04 Solae, Llc Vegetable protein meat analog
JP4802181B2 (ja) 2007-12-13 2011-10-26 アイシン高丘株式会社 搬送装置及びそれを有する熱間プレス成形装置
PT2706867T (pt) 2011-05-13 2018-06-12 Ojah B V Método de fabrico de composições de proteína estruturada
US8877277B2 (en) * 2011-11-29 2014-11-04 Frito-Lay North America, Inc. Supercritical fluid extrusion method, apparatus and system for making a food product
DE102014107610A1 (de) * 2014-05-28 2015-12-03 Emsland-Stärke GmbH Verwendung eines Nahrungsmittelprodukts aus stärkehaltigen Pflanzenteilen
PT3270716T (pt) 2015-03-20 2020-07-21 Nestle Sa Processo de preparação de um produto alimentar análogo a carne
DE102016111518A1 (de) 2015-11-12 2017-05-18 ETH Zürich Aufgeschäumtes teigbasiertes Lebensmittelprodukt sowie Vorrichtung und Verfahren zur Herstellung des aufgeschäumten teigbasierten Lebensmittelprodukts
US11166477B2 (en) 2016-04-14 2021-11-09 Mycotechnology, Inc. Myceliated vegetable protein and food compositions comprising same
KR20200140499A (ko) 2019-06-07 2020-12-16 공주대학교 산학협력단 냉각사출구를 이용한 압출성형 공정에 의한 수분 조절 인조육의 제조방법
EP3782475A1 (fr) * 2019-08-20 2021-02-24 Bühler AG Procédé de fabrication de denrées alimentaires contenant des protéines
MX2022002067A (es) * 2019-08-20 2022-03-17 Buehler Ag Metodo para la produccion de alimentos que contienen proteinas.

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