EP4601481A1

EP4601481A1 - Anisotropic structure creation for gel-like plant based meat and fish analogues

Info

Publication number: EP4601481A1
Application number: EP23787129.8A
Authority: EP
Inventors: Yu-Jie Wang; Katharina HINRICHS; Julien HUGO; Sarah MICHEL; Jean-Claude DELASOIE
Original assignee: Societe des Produits Nestle SA; Nestle SA
Current assignee: Societe des Produits Nestle SA; Nestle SA
Priority date: 2022-10-14
Filing date: 2023-10-12
Publication date: 2025-08-20
Also published as: IL318311A; WO2024079272A1

Abstract

The invention relates to a method of making a plant based seafood analogue, said process comprising the steps of applying at least a portion of a first dough mixture to a mold, wherein said dough mixture when applied has a viscosity at rest of between 1 Pa·s to 1000 Pa·s; applying at least a portion of a second dough mixture on the surface of the first dough mixture to create a layer which at least partially displaces the first dough mixture in the mold, and wherein said dough mixture when applied has a viscosity at rest of between 1 Pa·s to 1000 Pa·s; optionally applying further dough mixtures, wherein said dough mixtures when applied have a viscosity at rest of between 1 Pa·s to 1000 Pa·s; repeating steps a), b), and optionally c); and gelling the dough mixtures in the mold to form a plant based seafood analogue.

Description

Anisotropic structure creation for gel-like plant based meat and fish analogues

Introduction

Microstructural properties in food gels determine their textural features. Structure is a physical or chemical property of a system, while texture describes the macroscopically sensory perceptible effect as a consequence of microscopic structure. Texture is one of the most important properties which influence consumer acceptance. Thus, it is important to understand the relationship between the perception of food gel texture and its structure for the design of attractive gelled food products.

Food structure influences the appearance as well as the perception of texture and flavor. Structure in food can be created, for example, by 3D printing. This is an advanced way to generate complete structure or shape. However, the process relies on moving the nozzles or the supporting plate and is still limited for upscaling and industrialization.

Layering can be used to create structure in food. This technology is mainly used in the cake or confectionery industry, but also to prepare lasagna and other convenience food. The structure is typically created by different masses. Layers are created by alternately dosing and spreading. In this case the generated layers can vary in height and number but are mainly straight and parallel to each other. The structure is mainly created in two dimensions, for example the x and y dimensions.

In food originating from animals, like pieces of meat or fish fillet with solid or gel like texture, the pattern created by alternating muscle and connective tissue are not in a straight parallel formation, and in some cases like raw salmon, there is no sharp separation between the layers. Instead, the structure and pattern of muscle and connective tissue is irregular, of varied thickness, wavy, curved and connected to each other, like in animal based raw salmon products.

There are no plant-based fish or meat analogue currently existing that come close to the natural appearance of the real animal benchmark in terms of its appearance and inner structure.

Summary of Invention

The present invention relates to a method of preparing a plant based seafood analogue which mimics the structure and appearance of the muscle and connective tissue, particularly of animal based fish fillet. It provides a natural appearance due to curved and wavy layers. There is also a variability of layer thickness and layer distance. Slight mixing or transmission is permitted between layers, thus avoiding any unwanted sharp boundaries. It gives a greater guarantee that layers stick together, thus avoiding separation.

Structure is typically created by controlling the flow of two or more masses in an alternating way to create curved, wavy layers. Layer thickness and distance between one layer and the next can vary from one point in the layer to another one. In addition, this technology avoids separation of layers and helps the layers stick together and remain stuck, for example while cutting the final product into slices. Depending on the set-up, transition between layers can be created, including a fading / increasing coloration, which provides a more natural appearance. It is also possible to create layers that are across x, y, and z-axes.

The invention relates in general to a method of making a plant based seafood analogue, said method comprising the steps a. Applying at least a portion of a first dough mixture to a mold; b. Applying at least a portion of a second dough mixture on the surface of the first dough mixture; and c. Optionally applying further dough mixtures.

In some embodiments, said method comprises the steps a. Applying at least a portion of a first dough mixture to a mold, wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; b. Applying at least a portion of a second dough mixture on the surface of the first dough mixture to create a layer which at least partially displaces the first dough mixture in the mold, and wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; c. Optionally applying further dough mixtures, wherein said dough mixtures when applied have a viscosity at rest of between IPa-s to 1000 Pa-s; d. Repeating steps a), b), and optionally c).

In some embodiments, said method comprises the steps a. Applying at least a portion of a first dough mixture to a mold, wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; b. Applying at least a portion of a second dough mixture on the surface of the first dough mixture to create a layer which at least partially displaces the first dough mixture in the mold, and wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; c. Optionally applying further dough mixtures, wherein said dough mixtures when applied have a viscosity at rest of between IPa-s to 1000 Pa-s; d. Repeating steps a), b), and optionally c); and e. Gelling the dough mixtures in the mold to form a plant based seafood analogue.

The invention relates in general to a method of making a plant based seafood analogue, said method comprising the steps a. Applying at least a portion of a first dough mixture to a mold, wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; b. Applying at least a portion of a second dough mixture on the surface of the first dough mixture to create a layer which at least partially displaces the first dough mixture in the mold, and wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; c. Optionally applying further dough mixtures, wherein said dough mixtures when applied have a viscosity at rest of between IPa-s to 1000 Pa-s; d. Repeating steps a), b), and optionally c); and e. Gelling the dough mixtures in the mold to form a plant based seafood analogue.

In some embodiments, the first, second, and optionally other dough mixtures are applied to the mold using the same nozzle.

In some embodiments, the nozzle is located in a substantially central position above the mold.

In some embodiments, the first, second, and optionally other dough mixtures are applied to the mold using different nozzles.

In some embodiments, the different nozzles are located substantially equidistant from the center of the mold.

In some embodiments, the nozzle or nozzles remain stationary during dough mixture application. In some embodiments, the mold remains stationery during dough mixture application.

In some embodiments, the viscosity at rest of the first dough mixture when applied is between 1 to 1000 Pa-s.

In some embodiments, the gelled dough mixtures have different resistance to force application after gelling, for example by (i) cutting; and/or (ii) melting upon heating; and/or (iii) breaking upon freezing.

In some embodiments, the gelled dough mixtures have a different color, texture, thickness, or flavor.

In some embodiments, steps a), b), and c) are repeated so that at least 3 layers, or at least 5 layers of each dough mixture are obtained.

In some embodiments, the average thickness of each layer varies with the other layers.

In some embodiments, the mold imparts a fish shape.

In some embodiments, the mold has a height of at least 2 cm, preferably between 3 to 3.5 cm.

The invention further relates to a plant based seafood analogue, made by a method according to the invention.

In some embodiments, said analogue comprises alginate and is either a salmon analogue or white fish analogue.

In some embodiments, said analogue is a salmon analogue further comprising carrageenan and konjac.

The invention further relates to a system for making a plant based seafood analogue, said system comprising a. A first receptacle for holding a first dough mixture and a second receptacle for holding a second dough mixture; b. A first pump for transporting the first dough mixture and a second pump for transporting the second dough mixture; c. A mold; d. One or more nozzles for applying at least a portion of the dough mixtures into the mold; and wherein the system is adapted so that the dough mixtures are transported from the receptacles to the one or more nozzles, and wherein the one or more nozzles are adapted to apply at least a part of the first dough mixture and at least a part of the second dough mixture into the mold.

In some embodiments, the system is adapted so that at least a part of the first dough mixture and at least a part of the second dough mixture are applied in an alternate fashion into the mold.

In some embodiments, the system is adapted so that at least a portion of the first dough and at least a part of the second dough mixture are applied into the mold by the same nozzle. The nozzle may be a Y-shaped nozzle which receives dough mixtures through more than one entrance to the nozzle via tubing from separate tanks.

In some embodiments, the system is adapted so that at least a portion of the first dough and at least a part of the second dough mixture are applied into the mold by different nozzles.

The invention further relates to a method of making a plant based seafood analogue according to the invention using the system as described herein.

Detailed description of invention

Method of making a plant based seafood analogue

Typically, a minimum of two masses or dough mixtures are prepared and transferred to storage tanks. Each tank contains one mass. The set-up should ensure that the flowability of the masses is guaranteed, for example by temperature control to maintain flowable viscosity of the mass inside the tank. The required amount of mass can be pumped from each tank towards a depositor, preferably a nozzle, and dosed into a mold or packaging which is placed below the depositor.

Cold dough or hot dough can be used with different recipes for layering. The viscosity and yield stress of the mass is important. Some doughs having the same viscosity value at higher temperature can work as well. It is important to have the correct viscosity and thickness, which can be tuned by recipe and temperature as described herein.

The dosing amount and frequency is controlled by (i) the time the valves before the nozzle outlet are open; and (ii) the set throughput. Two or more masses are dosed in an alternate rhythm. The location and number of nozzles can be changed to obtain different pattern and structures on the surface and inside the final product, as described herein. A plant based seafood analogue mimics the structure and appearance of the muscle and connective tissue of an animal based seafood, for example particularly of animal based raw salmon, including smoked salmon, and tuna.

In some embodiments the invention relates to a method of making a plant based salmon analogue. A portion of a first dough mixture or mass is dosed or applied in a mold or container. A portion of a second dough mixture or mass is then dosed or applied on top of the first dough mixture or mass to create a layer which at least partially displaces the first dough mixture or mass in the mold or container. These steps are repeated, for example until the mold or container is full. The dough mixtures or masses are gelled in the mold or container to form a plant based salmon analogue. The gelling solidifies the created layered structure and freezes the 3D structure. The dough mixtures or masses may be gelled, for example, by cold-set gelation, heatset gelation, or ion induced gelation.

Referring to Figures 2 to 4, tanks 1 and 2 store an orange or first mass 3 and a white or second mass 4 respectively. The tanks may alternatively store any colored mass, for example purple mass or brown mass. Pumps 5 and 6 are located between the tanks 1 and 2 and the dozing nozzles 7, 14, and 15. Tubing suitable for transporting the dough mixture connects the tanks to the pumps and the pumps to the nozzles. Single valves 12 and 13 or three way valve 8 are located between tanks 1 and 2. A mold or container 11 is located under the nozzle to collect the applied orange mass 9 and white mass 10. Preferably, the distance between the nozzles and mold or container 11 is as short as possible.

Referring to figure 2, the method of making a seafood analogue comprises the steps of applying at least a portion of the first and second mass, for example by pumps 5 and 6 from tanks 1 and 2 to dosing nozzle 7 and 14. Three way valve 8 may be used to control the dosing amount. It allows a minor mixing of the two masses before dosing. The mixing degree can be controlled by the nozzle length. The dosing nozzle length can be about 50 mm. The nozzle diameter can be about 10 mm. The throughput can be about 25 kg/ h.

Referring to figure 3, the method of making a seafood analogue comprises the steps of applying at least a portion of the first and second mass, for example by pumps 5 and 6 from tanks 1 and 2 to dosing nozzles 7 and 14. Single valves 12 and 13 may be used to control the dosing amount.

Valve 12 between tank 1 and nozzle can be opened, for example, for 5 seconds and a portion of orange mass 3 from tank 1 can be applied at a typical throughput of 25 kg/h as orange mass 9 to mold 11. Valve 13 between tank 2 and nozzle can then be opened, for example for 5 seconds, and a portion of white mass 4 from tank 2 is applied at a typical throughput of 25 kg/h as white mass 10 to mold 11.

Alternate opening and closing the valves 12 and 13 is repeated until the mold 11 is filled to the desired level. Throughput and time of opening the valves can be adjusted to the mold volume and the desired number of layers. The dosing nozzle diameter can have, for example, a diameter of about 10 mm. Other diameters may be chosen to fit to the throughput and mold volume and dimension. Valves 12 and 13 can be manual or automatic. Dosing nozzles 7 and 14 are arranged separately above the mold.

Nozzles can be multiplied and fill into one mold in parallel. Referring to figure 4, nozzle 15 applies the masses at different positions above the mold. The flow of the dosed mass 9 and 10 from one nozzle is limited by the flow of the simultaneously dosed mass from the other nozzle.

Process parameters can be used to control appearance and structure, for example dosing amount, dosing frequency and number of dosages and position of nozzle above the mold. Dosing amount can be used to vary layer thickness. Typically, between 4 to 8 dosings of each mass are applied.

In some embodiments, the first dough mixture is red or orange and the second dough mixture is white. The ratio of amounts applied of the first dough mixture to the second dough mixture can be about 5:4 or about 4:3 or about 3:2 or preferably about 2:1. The throughputs of the first dough mixture and the second dough mixture may differ by up to 10%, 20%, 30%, 40%, or 50%. The dosing amounts and frequency may be similar to that shown in table 1. In some embodiments, the dosing time for each mass is between 2 to 5 seconds. Typically, the dosing time for the application of the first dough mixture is about 5 seconds. The complete dosing cycle may take about 26 seconds. The throughput for at least one of the dough mixtures may be about 25 kg/h. In some embodiments, a volume of between 180 g to 1000 g would be dosed in total for all masses. When the plant based seafood analogue is salmon, then typically between 4 to 6 layers are applied. The nozzle can be in a central position above the mold, or in an off center position above the mold.

The viscosity at rest range is between 1 Pas to 1000 Pa-s, preferably 5 Pas and 100 Pa s, preferably about 10 Pa s. Liquid Honey is about 10 Pa s, which is the preferred viscosity at rest of the mass. The viscosity at rest of the first, second, and optional further dough mixtures can be different but do not vary by more than 50%. The dough masses are flowable. The viscosity at rest of the dough masses typically do not vary by more than 10%, 20%, 30%, 40%, or 50%.

The term viscosity at rest is defined by the viscosity which is obtained by rheology measurement when extrapolated to a shear rate of 0 sec 1, or the shear rheology at 0.1 sec-1.

In one embodiment, the applied shear on the mass being dosed is greater than the yield stress of the other mass. Preferably, the viscosity at rest of the masses are within the range of 10 Pa-s to 100 Pa-s for plant based salmon analogues. In one embodiment, a mass when applied on top of the previous mass displaces the previous mass without significant mixing. After each dosing the surface is substantially flat.

In one embodiment, the masses are applied at different temperatures. In some embodiments, the total solid content of the dough masses differs by up to 50%, or up to 40%, or up to 30%, or up to 20%, or up to 10%. In some embodiments, the density of the dough masses differs by up to 50%, or up to 40%, or up to 30%, or up to 20%, or up to 10%. In some embodiments, the masses or dough mixtures are prepared by hydrating dry ingredients in water. The hydrated ingredients may then be heated to about 90°C. Colorant, flavor and DHA oil may then be added before mixing. The dry ingredients may comprise one or more of konjac powder, kappa carrageenan, potato starch, and soy protein isolate. The amounts of the dry ingredients may be substantially as shown in table 2. The viscosity at rest of the masses may be substantially the same as those shown in the examples. Typically, the density and gelling properties of the masses are different. The gel strength of one of the masses, for example the white mass, may be more solid-like compared to the other mass, for example compared to the orange or red mass. The dosing temperature of each mass may be between 60 to 90°C. The dosing temperature of the white mass may be about 80°C and the dosing temperature of the other mass, for example the orange or red mass, may be about 70°C. The dosing temperature is the temperature of the mass when it exits the nozzle.

In some embodiments, the plant based seafood analogue is plant based salmon with alginate. In some embodiments, the masses or dough mixtures are prepared by hydrating dry ingredients in water. Colorant may then be added before mixing. The dry ingredients may comprise one or more of alginate, rice protein, and soy protein isolate. The amounts of the dry ingredients may be substantially as shown in table 3. Gelling may occur by heating for about 50 minutes at about 100 °C.

In some embodiments, the plant based seafood analogue is plant based salmon with alginate and carrageenan. In some embodiments, the masses or dough mixtures are prepared by hydrating dry ingredients in water. Colorant may then be added before mixing. The dry ingredients may comprise one or more of alginate, rice protein, and soy protein isolate. Dry ingredients for a transparent mass may comprise konjac powder, kappa carrageenan, and potassium chloride. The amounts of the dry ingredients may be substantially as shown in table 4. Gelling may occur by heating for about 50 minutes at about 100 °C.

In some embodiments, the plant based seafood analogue is a white fish based on alginate. In some embodiments, the masses or dough mixtures for the white flesh are prepared by hydrating soy protein in water. Oil, for example sunflower oil, may then be added whilst shear mixing. Rice protein, alginate and sodium chloride may then be added and hydrated for about 20 minutes. Encapsulated calcium lactate can be added shortly before the dough is layered. The amounts of the ingredients may be substantially as shown in table 5. For connective tissue preparation, soy protein may be suspended in water for about 15 minutes. Oil may be added under shear mixing.

In some embodiments, the doughs are dosed alternatively in a mold and cooked at about 100°C for about 50 minutes, followed by cooling. Before consumption the product can be cooked in a pan or oven.

In some embodiments, the plant based seafood analogue is a plant based salmon based on pea starch. In some embodiments, the white mass or dough mixture is prepared by mixing pea starch and salt in water and heated to about 80°C. Orange mass was prepared in the same way but with the added step of mixing in colorant. The amounts of the ingredients may be substantially as shown in table 6.

Where the plant based seafood analogue is a salmon analogue, the yield stress of each dough is about 200 Pa. Where the analogue is based on alginate, the yield stress is about 700 Pa. Connective tissue has a yield stress of about 150 Pa. Uncooked dough, for example uncooked orange dough, has a yield stress of about 1000 Pa.

In some embodiments, the apparent viscosity, yield stress and viscoelastic dough properties are measured with a rheometer, for example an Anton Paar MCR 702 rheometer. The geometries and measurement conditions used can be those described in table 7.

EXAMPLES

Example 1

Process to create a salmon analogue

The following steps were followed to create a salmon analogue with a layered structure according to the invention. Starting from the left, Figure 1 shows an empty container (a) into which a first portion of mass was dosed (b). A portion of a second mass was then dosed on top of the first mass(c), which led to a displacement of the first mass. These two steps were repeated until the mold was filled and multiple layers were created (d). Finally, gelation was induced to solidify the created layered structure and freeze the 3D structure. Gelling was induced, for example, by cold-set gelation, heat-set gelation, or ion induced gelation.

Example 2

Effect of nozzle number, nozzle location and downstream design

In real salmon, the structure of connective tissue and muscle flesh varies in the orientation in three dimensions and this was able to be mimicked for a plant-based salmon alternative.

Figures 2 to 4 show different set-ups that allow an alternate dosing of two masses. An orange mass (3) and a white mass (4) are each stored separately in a tank (1,2). Each mass is transported either by gravity or by a pump (5,6) from the tank to the dosing nozzle (7, 14 ,15). Between tank and nozzle, a single valve (12, 13) or three-way valve (8) is installed to control the dosing amount. In general, the nozzle should have lowest distance as possible to the mold (11), to avoid splashing or air bubbles. Below the nozzle a mold (11) is placed where orange mass (9) and white mass (10) are collected. Figure 2 illustrates a process where dosing is started with a portion of orange mass (3), meaning the valve (12) connected with the orange tank (1) is opened for 5 seconds at throughput of 25 kg/h. This step is followed by opening the valve (13) for 5 seconds which controls the flow of the white mass (4). This alternate operation of opening and closing the valves of the two tanks is repeated until the mold (11) is filled to the desired level. Throughput and time of opening the valves can be adjusted to the mold volume and the desired number of layers. For the dosing nozzle diameter, a diameter of 10 mm was chosen, in order to fit to the throughput and the mold volume and dimension. Valves can be manually or automatically controlled.

The dosing nozzle (7, 14) from each tank can finish separately above the mold in Figure 2 or can be connected as shown in Figure 3 by a three-way valve (8) ending in one nozzle (7). That allows a minor mixing of the two masses before dosing. The mixing degree can be controlled by the nozzle length. The longer the nozzle after the three-way valve (8), the more distance where the doughs can mix. For the product shown in Figure 3, the dosing nozzle length (7) was chosen at 50 mm, nozzle diameter 10 mm, run with a throughput of 25 kg/ h.

The combined nozzle set-up of Figure 3 provides smooth transition between the two (or more) masses and delivers more natural appearance (preferred option) and may help sticking the two masses together depending on the dough composition. Both nozzle set-up from Figure 2 and Figure 3 and resulting images of product made by the respective set-up (throughput 25 kg/ h) are shown below each drawing.

Example 3

Pattern creation

The set-ups in Figures 2 and 3 result in only one inner structure. However real salmon fillet pieces usually have structure in two opposite directions or multiple wavy elements next to each other. To mimic this, nozzle set-ups from Figures 2 and 3 can be multiplied and fill into one mold in parallel. The set-up in Figure 4 is a multiplied combined nozzle set up from Figure 3, delivering a product structure as shown in the corresponding photo in Figure 4. The corresponding nozzle (15) ends therefore at different positions above the mold. Two or more inner structures which are connected will be created, since the flow of the dosed mass from one nozzle is limited by the flow of the simultaneously dosed mass from the other nozzle. In general, multiplying the nozzles above one mold keeping throughput constant can help to decrease the required time to fill.

Example 4

Control of appearance and structure by process parameters: dosing amount, dosing frequency, number of dosages, and position of nozzle above the mold Surface appearance and inside structure are anisotropic and vary in the animal benchmark by species, overall animal size. Also, inside the animal, one can observe thicker and thinner layers of red flesh or white connective tissue. This means per volume of animal, there are more or fewer layers. With the designed dosing system, layer thickness can be adjusted by the dosed mass volume. The more dosed per alternating dosing step, the thicker the layers. In general, dosed volume needs to be adjusted to the mold volume. In total between 4-8 dosings of each mass should fit into the mold to obtain a real salmon like structure.

Ratio of the different masses can be adjusted towards the wished result. If the ratio between red and orange is kept at 2 (orange): 1 (white) or less, it matches the animal benchmark. For mimicking this variability of layer number and thickness, one can adjust the ratio of one mass to the other one(s) or the throughput of each dough. This ratio/dosing frequency needs to fit to the throughput and can be kept constant or be increased or decreased during one dosing cycle to fill one mold. If one wants to approach regular distances between the layers from bottom to top, a decreasing frequency is beneficial since the mold is more and more filled and the area where the masses flow gets smaller. Dosing amounts at a given frequency as shown in Table 1 result in regular layer thickness as shown in figure 5. The complete dosing cycle takes 26 seconds and if run with a throughput of 25 kg/h a volume of 180 g would be dosed in total. In general dosing amount and frequency should be adapted to the mold volume to meet the targeted layer thickness fitting to the number of layers.

Table 1: Dosing frequency of orange and white mass

The number of layers depends on frequency of dosing and alteration, package dimension for example the height. The thickness of the layer depends on the volume of each layer. Figure 6 shows an example gel with a variation of layer thickness, which was obtained by changing the dosing amount from 5 s (bottom layers) to 15 seconds (top layers), throughput 25 kg/h, mold volume 1000 g. For plant based salmon analogues 4-6 layers fit best the animal benchmark.

Nozzle position can be centered or random in the mold. Centered position gives a more regular flow resulting in a more symmetric pattern, while random nozzle position gives a more asymmetric pattern, since the flow of each portion of dosed mass could be stopped in one or multiple direction by the packaging side wall.

Example 5

Control of appearance and structure by dough properties

The process requires a minimum of two flowable masses, in best case with similar viscosity at rest range to enable the desired 3D curved structure creation by alternate dosing. The term viscosity at rest is defined by the viscosity which is obtained by rheology measurement when extrapolated to a shear rate of 0 rad/sec, or the shear rheology at 0,1 rad/sec.

In addition, for the process it is required that the applied shear on the dough being dosed is high enough to be greater than the yield stress of the other dough, otherwise it will not flow. A dough without a yield stress will neither set nor displace the first layer.

The viscosity at rest of both masses within a range of 10 Pa-s to 100 Pa-s provided the right flowing properties and conditions to mimic raw salmon structure.

Only in the given viscosity at rest range the mass portion when dosed on top of the previous mass portion displaces the below mass without mixing. After each dosing the surface is flattened due to the flowability and alternate displacement of the masses.

If the dough is too viscous, the flow of the mass will be too slow and the masses would not displace each other during stepwise dosing and thus only create parallel horizontal (thick) layers instead of curved ones. If the dough is too thin, the two masses will mix inside the mold and no layered structure would be created.

It is preferred if both masses are within the given range of viscosity at rest, this allows uniform layering with uniform layer thickness. If one wants to change layer thickness, this can be done by variation of the dosing amount.

However, if one mass has very different viscosity in comparison to the other, the flow property will be different, the lower viscosity mass cannot displace the mass with higher viscosity. Instead, it would distribute out of control, e.g. as a (uneven) layer on the below mass. That means the final structure would not be completed, layer thickness is not uniform, and layers would not be curved, not being able to mimic the animal benchmark appearance and texture.

In non-Newtonian fluids (most food) viscosity is a function of temperature, so temperature changes can be used to control the viscosity. Additionally, the constitution of the mass (ingredient type and concentration) can control the viscosity. These two options can be used to adjust the viscosity at rest of the two or more masses used to build structure.

Besides viscosity at rest being in the same range, it is also beneficial to operate in the same range of density of the two or more masses. If one mass is significant lighter than the other one, displacement would not happen to the extent required, since the lighter mass will accumulate on the surface.

Example 6

Plant based salmon using lower viscosity mass

The viscosity at 85 °C of the orange dough and the white dough were measured as a function of shear rate (Figure 8).

The impact of temperature on the orange dough on the yield stress was measured at 25 and at 85°C (Figure 9).

Plant based salmon was made with an orange mass and a white mass. The recipes are listed below in Table 2.

Table 2: Formulation for plant-based salmon based on carrageenan gelation.

The orange mass and white mass were prepared separately. For each mass, dry ingredients were hydrated in water, followed by heating to 90 °C. Colorant, flavor were added at the end of the heating and mixed homogenously. Both masses were dosed following the process described in Example 1. The viscosity of the orange and white mass at 75 °C is shown in Figure 8.

In order to approach the viscosities at rest of the two masses towards each other, temperature of the white mass was increased to 80 °C as dosing temperature, while the orange mass was dosed at 70 °C. This facilitated dosing operation. The final gels of the orange and white mass had different gel properties. The elastic modulus (G') which indicates the gel strength showed that the white dough was more solid-like compared to the orange dough (Figure 10), and instrumental textural analysis also indicated textural differences (Figure 11). The hardness of the white gel is higher than the orange gel which resembles the difference between flesh and connective tissue in the animal benchmark. Texture was analyzed by instrumental textural analysis following the analysis method described in the methods chapter.

Example 7

Plant based salmon with alginate

Plant based salmon with alginate (high in viscosity) was created by the following recipe shown in Table 3.

Table 3: Formulation for plant based salmon based on alginate gelation.

All dry ingredients were weighed and added portion-wise on stirred tap water until well dispersed, then mixing speed was reduced and mixing was continued for 20 min. For the orange mass, the colorant was added and mixed until homogenously distributed. Zebra motives were obtained by alternatively dosing white and colored dough portions into a mold. The gel was set by cooking in a fan oven for 50 min at 100 °C.

Both doughs prepared by this recipe and process, were higher in viscosity at rest than the doughs obtained from the recipe in example 6. This higher viscosity limited the flow (speed) of the doughs and the displacement of the earlier dosed dough by addition of the next dough. Resulting layers were thick and also less curved as shown in Figure 12, which do not meet the appearance of the animal benchmark appearance. However, the desired salmon like pattern was obtained. Example 8

Layering with alginate - white fish prototype

A white fish prototype was created by the following recipe shown in Table 5.

Table 5: Formulation for white fish prototype based on layering with alginate.

For white flesh preparation, soy protein was hydrated in water for 15 min in a Thermomix, the oil was added slowly and the shear was increased to the maximum for 1 min. The remaining dry powders (except the calcium salt) were added and hydrated for 20 min. The salt was added right before using the dough for layering.

For connective tissue preparation, the protein was suspended in water for 15 min, then the oil was added slowly and the speed was increased to the maximum progressively and maintained for 1 min. the dough was mixed with a spatula and mixed to maximum speed for 1 min one more time.

For the layering, both doughs were dosed alternatively in a mold and cooked in a fan oven at 100°C for 50 min and let cool down to 4 °C in fridge or freezer. Before consumption the product could be cooked on a pan or in the oven. In this case the viscosity of the connective tissue dough is much lower than the alginate (Figure 7) so that the connective layers can be very thin. Both layers have very different textures, as shown in Figure 15. Texture was analyzed by instrumental textural analysis following the analysis method described in the methods chapter.

The final visual of the alginate sample is presented in Figure 13.

Example 9

Layering with starch base Plant based salmon was created by the following recipe shown in Table 6.

Table 6: Formulation for plant based salmon based on starch gelation.

A dry mix of pea starch and salts were dispersed in cold water, and then heated to 80°C while mixing to obtain the white mass. For the orange mass, the colorant was added after heating and mixed until homogenously distributed. Two hot doughs were used to dose into a mold alternatively. Viscosity at rest was comparable to the carrageenan based dough, so obtaining thin layers was possible, creating natural appearance.

After cooling in fridge (4 °C) overnight, a gel with insides marbled structure as shown in Figure 14 was formed. The uncolored dough became opaque and white, quite close to the animal benchmark.

Methods

The apparent viscosity, yield stress and viscoelastic properties of all of the doughs described throughout the examples were measured with an Anton Paar MCR 702 rheometer. The geometries and measurement conditions used are described in table 7 below.

Table 7

Instrumental texture analysis

For all studies described in the examples, texture of the gels was characterized by destructive instrumental Texture Analysis by TA-XT2 Texture Analyzer (Stable Micro Systems, Surrey, England) with a 5 kg load cell. The instrument was controlled by a computer using the software EXPONENT Connect Version 7.0.3.0 that allows test setup as well as data analysis via test specific macros analyzing force-distance curves.

All instrumental texture analysis were conducted one day after dough preparation and layering, and consecutive gelation was induced by cooling or by heating of the masses in fridge (6 °C). Before instrumental texture analysis the gel samples were equilibrated to room temperature and cut to a defined shape. The force required to break the gel samples by penetration with a cylindrical probe of a diameter of 0.9 cm was recorded as gel hardness (maximum peak force in force-deformation curve).

Claims

1. A method of making a plant based seafood analogue, said method comprising the steps a. Applying at least a portion of a first dough mixture to a mold, wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; b. Applying at least a portion of a second dough mixture on the surface of the first dough mixture to create a layer which at least partially displaces the first dough mixture in the mold, and wherein said dough mixture when applied has a viscosity at rest of between 1 Pa-s to 1000 Pa-s; c. Optionally applying further dough mixtures, wherein said dough mixtures when applied have a viscosity at rest of between IPa-s to 1000 Pa-s; d. Repeating steps a), b), and optionally c); and e. Gelling the dough mixtures in the mold to form a plant based seafood analogue.

2. The method according to claim 1, wherein the first, second, and optionally other dough mixtures are applied to the mold using the same nozzle.

3. The method according to any one of claims 1 and 2, wherein the nozzle is located in a substantially central position above the mold.

4. The method according to any claim 1, wherein the first, second, and optionally other dough mixtures are applied to the mold using different nozzles.

5. The method according to claim 4, wherein the different nozzles are located substantially equidistant from the center of the mold.

6. The method according to any one of claims 1 to 5, wherein the viscosity at rest of the first dough mixture when applied is between 1 to 1000 Pa-s.

7. The method according to any one of claims 1 to 6, wherein at least one of the dough mixtures comprise alginate.

8. The method according to claim 7, wherein at least one of the dough mixtures further comprises carrageenan or konjac.

9. The method according to anyone of claims I to 8, wherein steps a), b), and c) are repeated so that at least 3 layers, or at least 5 layers of each dough mixture are obtained. A plant based seafood analogue, made by a method according to any one of claims 1 to 9. The plant based seafood analogue according to claim 10, wherein said analogue comprises alginate and is either a salmon analogue or white fish analogue. The plant based seafood analogue according to any one of claims 10 to 11, wherein said analogue is a salmon analogue further comprising carrageenan and konjac. A system for making a plant based seafood analogue, said system comprising a. A first receptacle for holding a first dough mixture and a second receptacle for holding a second dough mixture; b. A first pump for transporting the first dough mixture and a second pump for transporting the second dough mixture; c. A mold; d. One or more nozzles for applying at least a portion of the dough mixtures into the mold; and wherein the system is adapted so that the dough mixtures are transported from the receptacles to the one or more nozzles, and wherein the one or more nozzles are adapted to apply at least a part of the first dough mixture and at least a part of the second dough mixture into the mold. The system according to claim 13, adapted so that at least a part of the first dough mixture and at least a part of the second dough mixture are applied in an alternate fashion into the mold. The system according to any one of claims 13 and 14, adapted so that at least a portion of the first dough and at least a part of the second dough mixture are applied into the mold by different nozzles. A method of making a plant based seafood analogue according to any one of claims 1 to 9 using the system of any one of claims 12 to 15.