EP4672978A1

EP4672978A1 - Meat analogues

Info

Publication number: EP4672978A1
Application number: EP24707456.0A
Authority: EP
Inventors: Cyan WILLIAMS; Ellen WRIGHT; Emily GAULT; Wanrui ZHANG; Luke Byrne
Original assignee: Plant Meat Ltd
Current assignee: Plant Meat Ltd
Priority date: 2023-02-28
Filing date: 2024-02-21
Publication date: 2026-01-07
Also published as: GB202302948D0; GB2627768A; WO2024179907A1

Abstract

Described herein are processes for preparing meat analogues. Also described are meat analogues comprising a fat composition and a protein component, and uses of a fat composition as a substitute for connective tissue in a meat analogue.

Description

MEAT ANALOGUES

FIELD OF THE INVENTION

The present invention relates to meat analogues having a substantially continuous network of a fat composition, and processes for preparing the same.

BACKGROUND

Demand for vegetarian and vegan food products has increased around the globe, as consumers become increasingly aware of the environmental impact of animal farming. Concerns around animal welfare also continue to influence consumer choices. As a result, there is high demand for meat-free and vegan food products.

Meat analogues are prepared such that they resemble meat as much as possible in appearance, taste and texture, whilst containing no ingredients of animal origin. Creating realistic meat analogues is technically challenging. “Whole cut” animal meat products, such as chicken legs or steak, have a complex three-dimensional architecture in which protein fibres are bound together by a network of collagenous connective tissue and intramuscular fat. This structure provides succulence (or juiciness) and a chewy texture when eaten.

Existing meat analogue products have so far been unable to successfully marry fat and protein components in a single product. One approach is to provide a two-dimensional fat/protein structure in which a layer of fat is applied to a layer of protein. A drawback of such approaches is that adhesion between the two layers is very difficult to achieve, and delamination (separation of the layers) occurs when the product is handled or cooked. A further drawback is that the product is not succulent or juicy, since there is no intermingling of the protein and fat components.

Another approach is to provide a set fat composition, chopped into pieces and mixed with a protein. However, such approaches do not recreate the three-dimensional intramuscular fat distribution seen in whole cuts of meat, and do not provide realistic-looking meat analogues. Binding of the components together is also difficult to achieve with this approach.

A further approach, as detailed in W02020152689, is to prepare meat analogues using 3D printing of both protein fibres and fat fibres. While this provides a meat analogue that appears to have a realistic fat distribution when sliced in a specific direction, again the distribution of fat does not extend in all three dimensions throughout the product and so does not faithfully recreate whole cuts of animal meat. This is apparent when the meat analogue is sliced in the wrong plane. As a result, the meat analogue is not succulent, and as with other approaches, the effect of the collagenous connective tissue in binding the components of a meat joint together is not reproduced. Other meat analogues are described in WO2022157584. In said meat analogues, a block of protein is prepared and subsequently compressed. Compression is performed with the aim of partially separating some of the fibres of the protein block. A binder, which may include a fat analogue, can then be applied to the protein block. In such meat analogues, the protein block remains intact as a single element or slab even after compression, with the binder interspersed between only some of the external fibres of the protein. Such meat analogues do not therefore have a distribution of fat throughout the meat analogue in a continuous way. Rather, the fat is contained only in individual pockets between some of the fibres. Said meat analogues therefore cannot recreate the texture of, for example, chicken drumsticks or wings. Said meat analogues also require an additional marinading step prior to the application of the binder, to provide flavour.

Other meat analogues are described in WO2022079717. Said meat analogues are formed of a plurality of protein strands and a plurality of “inter-strand sheath material”. The meat analogues are produced in an additive way, in which aligned protein strands are dispensed in a layer, the inter-strand sheath material is dispensed on top, and the process repeated until the desired size is reached. Forming the product in this way produces a meat analogue with a homogenous distribution of layers of precisely aligned protein strands. This in turn results in an ordered cross-section that is unlike real meat. Said meat analogues fail to recreate the non-homogenous matrix of fat and protein that is seen in real meat, and consequently cannot recreate the texture of meat products such as chicken drumsticks or wings.

The present invention overcomes these issues by providing meat analogues in which fat is distributed throughout the meat analogue in a realistic, three-dimensional, continuous network.

SUMMARY OF THE INVENTION

In a first aspect, the invention provides a process for preparing a meat analogue, comprising:

(a) providing a protein component, wherein the protein component comprises a plurality of pieces of a protein composition;

(b) combining an unset fat composition with the pieces of the protein composition and mixing to distribute the pieces within the unset fat composition and form a substantially continuous network of the fat composition; and

(c) setting the fat composition; wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water.

In a second aspect, the invention provides a meat analogue comprising a fat composition and a protein component, wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

In a third aspect, the invention provides a meat analogue produced by the process described herein.

In a fourth aspect, the invention provides the use of a fat composition as a substitute for connective tissue in a meat analogue, wherein the fat composition comprises a glucomannan gum, a fat, a browning agent, a coagulating agent, and water.

In a fifth aspect, the invention provides a process for preparing a meat analogue, comprising:

(a) combining an unset fat composition with an unset protein composition; and

(b) texturizing the mixture from (a), wherein the texturizing comprises mixing the protein composition within the unset fat composition to form a substantially continuous network of the fat composition; and wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water.

DETAILED DESCRIPTION

The present invention provides meat analogues having a protein component and a fat or fat composition. The meat analogues described herein are improved with respect to existing meat analogues in that the fat or fat composition is distributed throughout the protein component in a three- dimensional, substantially continuous network, and acts as a binding agent to hold or bind the protein component together. Importantly, the protein component is provided as fibrous pieces of protein, and binding arises through an interaction between the unset fat or fat composition and these fibrous protein pieces. This in turn provides a cohesive meat analogue, which holds its shape and has fat distributed between the pieces of the protein. In this way, the network of the fat composition provides two important benefits that are not seen in meat analogues of the art. Firstly, the network of the fat composition mimics the intramuscular fat observed in cuts or joints of animal meat, contributing to taste and texture. Secondly, the network of the fat also reproduces the effect of connective tissue in holding and binding the pieces (for example, strands, fibres or chunks) of protein together. As such, the network of the fat composition works as a replacement for both fat and connective tissue in meat analogues. In contrast to existing meat analogues, the fat or fat composition binds the whole structure of the meat analogue together (that is, it connects and binds all the protein pieces), rather than just forming separate pockets in the meat analogue.

Meat analogues with a three-dimensional, substantially continuous network of fat as described herein have an improved mouthfeel, appearance and taste compared to existing meat analogues. In particular, meat analogues as described herein are succulent and juicy, recreating the texture and succulence of animal meat products. Because of the characteristics of the fat composition, different- sized and irregular sized fibrous protein pieces can be used within the same meat analogue, since the fat composition binds them together in a cohesive way. Because of the three-dimensional, net-like distribution of the fat composition, meat analogues as described herein come apart in chunks or pieces when eaten, recreating the experience of eating animal meat such as a chicken drumstick or a chicken wing.

The processes for preparing meat analogues described herein mix unset (e.g. liquid) fat compositions with pieces of protein, in order to distribute and/or coat the protein pieces in the fat. Once set, the meat analogue has a continuous yet non-homogeneous distribution of fat throughout the product, to mimic the distribution seen in animal meat. Meat analogues as described herein provide realistic substitutes for meat products, in particular “whole cut” meat products such as chicken drumsticks and steak. Advantageously, characteristics of the pieces of the protein composition can be adapted to best imitate each type of meat analogue. For example, chicken drumstick or wing analogues can have larger pieces which come away in sections, whilst steak analogues may have smaller pieces to give a more steak-like texture.

Further advantages of the meat analogues provided herein are apparent during cooking and eating. Because the fat composition sets to a solid emulsion, it has a firming effect on the meat analogue. This firming effect is greater than that achieved with other plant-based fat emulsions using methylcellulose or konjac. For example, methylcellulose based fat replacers are not firm when chilled. The fat composition is also heat stable. This means that when the meat analogue is cooked, only a small amount of oil/fat is released with heat, such that the meat analogue maintains its solid structure during cooking. In comparison, other emulsions used as fat/connective tissue replacers, such as those based on methylcellulose, release a much greater proportion of oil on heating. Advantageously, with the meat analogues described herein the oil/fat is released from the fat composition in response to mechanical stress such as biting. This type of heat-stable encapsulation of the oil/fat in the fat composition provides succulence and a more realistic eating experience.

Processes for preparing meat analogues

The present invention provides processes for preparing meat analogues which have a substantially continuous network of fat. The processes of the invention comprise:

(c) setting the fat composition.

The protein component is of non-animal origin and provides the protein that would otherwise be provided by animal meat, for example from farmed animals. The protein component is generally provided as a plurality of pieces of a protein composition (i.e. at least two separate pieces but generally many separate pieces). The pieces can be shreds, strands, fibres, chunks, lumps, irregular pieces, or a combination thereof. The processes described herein can also include a first step of shredding or otherwise dividing a protein composition (such as a protein block or slab) to form a plurality of separate pieces of the protein composition. For example, a protein composition may be prepared in a single block, slab or piece by high moisture extrusion, or from textured vegetable protein, and subsequently shredded, minced, chopped or otherwise divided into a plurality of separate pieces. Alternatively, the pieces of the protein composition may be pre-formed. It will be noted that the pieces of the protein composition used in the invention can therefore be distinguished from other food products in which a fat is used to bind a protein paste or mixture, such as commonly seen in plant-based burger, sausage or meatball products. The invention can also be distinguished from meat analogues in which fat is applied to a single piece, such as a single slab, of protein.

The size of the pieces of the protein composition can be adapted based on the meat analogue being prepared, for example a chicken drumstick analogue may have larger pieces compared to a steak analogue. The pieces of the protein composition do not need to be of uniform size, and the meat analogues described herein can include pieces of varying sizes. Very large or very small pieces can generally be used, provided a majority of the pieces are within a preferred size range. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 15 cm in any dimension. That is, the pieces do not exceed 15 cm in height, width, depth, length, diameter, etc. It will also be understood that some forms of protein piece may be very large in one dimension, but be small in a second dimension. For example, a fibre or strand may have a length of 8 cm but a diameter or width of 0.5 cm. When the pieces of the protein composition are chunks or lumps, the size may be more similar in each dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 10 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 9 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 8 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 7 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 6 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 5 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 4 cm in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 3 cm in any dimension.

In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 15 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 10 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 9 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 8 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 7 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 6 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 5 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 4 cm in any dimension. In some embodiments, at least 50%, at least 60%, at least 80% or at least 90% of the pieces of the protein composition do not exceed 3 cm in any dimension.

Depending on the application, the pieces of the protein composition may be much larger than the sizes described above, and in some cases may be about 1 metre, 2 metres or 3 metres long. In some embodiments, the pieces of the protein composition do not exceed 3 metres in any dimension. In some embodiments, at least 70% of the pieces of the protein composition do not exceed 1 metre in any dimension.

Depending on the desired food application, the pieces of the protein composition may also have a minimum size in all dimensions. For example, in some embodiments at least 70% of the pieces of the protein composition are larger than 0.5 cm in all dimensions, larger than 1 cm in all dimensions, larger than 1 .5 cm in all dimensions, larger than 2 cm in all dimensions, larger than 3 cm in all dimensions, larger than 4 cm in all dimensions, larger than 5 cm in all dimensions, or larger than 6 cm in all dimensions.

The majority of the protein pieces may have a size within a preferred range. For example, at least 70% of the pieces of the protein composition may be between approximately 0.2 to 15 cm in any dimension (that is to say, the pieces are between 0.2 and 15 cm in all dimensions: length, height, width, etc). In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 10 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 9 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 8 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 7 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 6 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 5 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 4 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 0.2 to 3 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 6 to 15 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 6 to 12 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 6 to 10 cm in all dimensions. In some embodiments, at least 70% of the pieces of the protein composition are between approximately 6 to 9 cm in all dimensions.

The pieces of the protein composition are then combined with an unset fat composition. As used herein, “unset” refers to the fat composition in a form that can be poured, shaped, stirred or otherwise manipulated. The fat composition may be in a liquid form, or at an otherwise pourable viscosity, such as a gel or syrup. This enables the required distribution of the protein composition pieces within the fat during mixing, which in turn ensures that a three-dimensional, substantially continuous network of fat is achieved in the resulting meat analogue.

The pieces of the protein composition are combined with the unset fat and mixed to distribute the pieces within the unset fat composition. The unset fat composition should coat or cover each piece of protein. The fat composition then forms a continuous or substantially continuous global network within the meat analogue, to bind the meat analogue and hold the meat analogue together. By “continuous”, it is meant that the network is global and runs throughout the entire meat analogue product, in all three dimensions, in a substantially unbroken manner. The fat composition will be distributed in the meat analogue so as to form a net or web-like structure, binding the protein together. It is this continuous, net-like structure that allows chunks or pieces of the meat analogue to be pulled apart in a realistic way that imitates real meat.

The substantially continuous network of the fat composition may be an adherent network. In other words, it may adhere the components of the meat analogue together (for example, adheres the pieces of the protein composition together). The network of the fat composition may also be arranged to act as a binding agent. The network of the fat composition may be arranged to bind the pieces of the protein composition together. The fat composition may form a three-dimensional matrix within the meat analogue. The network of the fat composition may extend throughout the meat analogue in all directions.

The network of the fat composition may be arranged to act as a connective tissue. For example, the network of the fat composition may mimic the connective tissue that is found in cuts of animal meat or other animal meat products. This allows the meat analogue to be pulled apart in a realistic way when eaten.

The connective tissue-like properties of the fat composition (such as adherence and binding) can also be enhanced further with the addition of binding agents and/or adhering agents. Such agents include cold-set or heat-set gelling agents, dietary fibres, potato fibre, beta-glucan, arrowroot powder, chia seed powder, flax seed powder, psyllium husk, guar gum, xanthan gum, agar agar, carrageenan, modified starches, furcellaran, gellan gum, galactomannans, pectin, curdlan, xyloglucan, modified cellulose, konjac, microcrystalline cellulose, glucans, albumin, tapioca flour, potato starch, or combinations thereof. In some embodiments, the fat compositions described herein may include psyllium husk (also called psyllium, psyllium fibre, or psyllium husk fibre). In some embodiments, the fat compositions described herein may also include guar gum. In some embodiments, the fat compositions described herein may also include xanthan gum.

For vegetarian food products (as opposed to vegan food products), egg albumen can also be added to the meat analogue to improve its cohesive properties. Egg albumen can be used as part of the fat composition, or added as an additional step when the fat composition is mixed with the pieces of protein composition.

Mixing can be performed by any means known in the art. Alternatively, the fat composition can simply be combined with the pieces of protein composition. In comparison with existing meat analogues, the separate pieces of protein composition do not need to be layered or formed in a sandwich-like structure. Rather, the network of the fat composition holds the separate pieces together in any direction.

After mixing or combining, the fat composition is set. “Setting” as used herein refers to changing the fat composition into a solid or semi-solid state, for example such that it holds its shape without a mould. Once the fat composition has been set, the network of the fat composition binds the meat analogue together. Setting can be performed at room temperature, or alternatively can be achieved or accelerated by cooling or heating. Setting can preferably be performed in a mould to maintain the shape of the meat analogue. Setting can alternatively or additionally be performed by pressing the meat analogue into a desired shape. Setting can be performed according to any method known in the art, dependent on the type of fat composition(s) used in the meat analogue.

Alternatively, the meat analogue mixture may be stored after mixing or combining, without setting.

The processes described above utilise a “set” protein composition, such as a high moisture extrudate or textured vegetable protein. However, it is also possible to produce meat analogues having a network of a fat composition using both an unset fat composition and an unset protein composition. For example, the unset fat and protein compositions can be combined and the fibres formed with the unset fat. The compositions are then mixed and texturized to produce the substantially continuous network of the fat composition. After texturization, the mixture can be set to produce the meat analogue. Texturization can optionally be high temperature texturization. Texturization can optionally be performed in an extruder, wherein the mixture is extruded through a die. Texturization can optionally be performed using shear cell technology, wherein the mixture is sheared.

Therefore, in a further aspect, a process for preparing a meat analogue comprises:

(a) combining an unset fat composition with an unset protein composition; and (b) texturizing the mixture from (a), wherein the texturizing comprises mixing the protein composition within the unset fat composition to form a substantially continuous network of the fat composition; and wherein the fat composition comprises a glucomannan gum, a fat, a browning agent, a coagulating agent, and water.

Meat analogue

The invention also provides meat analogues having a substantially continuous network of a fat composition.

Meat analogues of the invention may comprise a fat composition and a protein component, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

As described above, the network of the fat composition may be an adherent network. The network of the fat composition may be arranged to act as a binding agent. The network of the fat composition may be arranged to bind the pieces of the protein composition together. The network of the fat composition may be arranged to act as a connective tissue. The network of the fat composition may be continuous or substantially continuous. The network of the fat composition may extend throughout the meat analogue.

Throughout this disclosure, “total weight of the meat analogue” refers to the weight of the meat analogue without any kind of coating, breading, skin, batter or similar.

The protein component of the meat analogues described herein may be present in an amount between approximately 5-40 wt.%, wherein wt.% is based on the total weight of the meat analogue. The fat composition of the meat analogues described herein may be present in an amount between approximately 1-40 wt.%, wherein wt.% is based on the total weight of the meat analogue. The amount of the fat composition can be varied according to the type of meat analogue. For example, for a chicken drumstick analogue, the fat composition may preferably be present in an amount between 15 and 20 wt.%. Advantageously, binding by the network of the fat composition can still be achieved at low % amounts of fat composition, such as between 1 and 10%, which can be useful if preparing “low-fat” meat analogue products.

The ratio of the amount of the at least one protein component to the amount of the fat composition is preferably between about 5:1 and 1 :10.

The meat analogues described herein or prepared according to a process of the invention may be a whole cut meat analogue, a chicken drumstick analogue, a chicken leg analogue, a chicken wing analogue, a steak analogue, a chicken analogue, a bacon analogue, a mincemeat analogue, a burger analogue, a sausage analogue, a meatball analogue, a beef analogue, a pork analogue, a lamb analogue, a sliced meat analogue, a chicken joint analogue, a pork joint analogue, a lamb joint analogue, a beef joint analogue, a roast joint analogue or a fish analogue. In a preferred embodiment, the meat analogue is a chicken drumstick analogue. In another preferred embodiment, the meat analogue is a chicken wing analogue. In another preferred embodiment, the meat analogue is a steak analogue. In another preferred embodiment, the meat analogue is a roast analogue.

The present invention also provides meat analogues obtainable by or produced by the processes described herein.

The present invention also provides the use of a fat composition as a substitute for connective tissue, or as a substitute for connective tissue and fat, in a meat analogue.

Fat composition

The fat composition may be any suitable fat composition of non-animal origin. Particularly suitable are those fat compositions that act as a binding agent. In particular, the fat composition may comprise a glucomannan gum, a fat, a browning agent, a coagulating agent, and water, such as described in PCT/EP2022/062217.

Processes of the invention may therefore comprise the following steps:

Meat analogues of the invention may comprise a fat composition and a protein component, wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

Preferably, the fat composition further comprises a browning agent.

The fat composition may comprise: 0.1 - 5 wt.% of the glucomannan gum;

2 - 25 wt.% of the fat;

0.01 - 5 wt.% of the coagulating agent;

45 - 93 wt.% water; wherein the wt.% is based on the total weight of the fat composition. The fat composition may further comprise 4 - 20 wt.% of a browning agent.

In the fat composition, the glucomannan gum may be konjac gum. Konjac gum is a water-soluble hydrocolloid obtained from konjac flour by aqueous extraction.

The browning agent is selected from the group consisting of xylose, arabinose, galactose, fructose, mannose, sucrose, dextrose, lactose, maltose and dextrin. Preferably, a dextrin is used. Dextrins can be produced from starch using enzymes like amylases, or by applying dry heat under acidic conditions. Preferably, a maize dextrin is used.

The coagulating agent is added to de-acylate the glucomannan gum to obtain an irreversible gel of the glucomannan gum. The coagulating agent is selected from sodium carbonate, potassium carbonate, potassium hydroxide, sodium hydroxide and calcium hydroxide. Preferably, calcium hydroxide is used.

Preferably, a plant based fat is used, preferably selected from the group consisting of shea butter, rapeseed oil, canola oil, corn oil, coconut fat, rice brain oil, safflower oil, sesame oil, peanut oil, sunflower oil, linseed oil, avocado oil, grape seed oil, olive oil, vegetable oil and palm fat, and mixtures thereof. The fat may be optionally fully or partly hydrogenated, although unsaturated fats are preferred for their health benefits. It is advantageous if the fat used has a melting point of less than 60 °C. Preferably, the fat is a liquid fat, i.e. a fat that is liquid at room temperature.

In a preferred embodiment, the glucomannan gum is konjac gum, the browning agent is dextrin, the coagulating agent is calcium hydroxide and the fat is a liquid fat, such as sunflower oil, vegetable oil or olive oil.

The glucomannan gum is preferably used in combination with one or more gelling agents. The gelling agent may be a hydrocolloid. Typical gelling agents are carrageenan gum, Jerusalem artichoke, psyllium husk, xanthan gum, agar, alginate, carboxymethyl cellulose, casein, guar gum, gellan gum, gelatin, gum arabic, locust bean gum and pectin.

Preferably xanthan gum, agar, guar gum or locust bean gum, more preferably xanthan gum is used as the gelling agent. Xanthan gum is a natural biopolymer produced by Xanthomonas campestris. The advantage of using xanthan gum is that it is tolerant of changes in pH and has a yield point, which means that under a certain stress, the behaviour of the gum changes from elastic to plastic, with a permanent change in shape. This allows capturing of fat globules. The weight ratio gelling agent/glucomannan gum is preferably from 0:100 to 15:85, preferably 2:98 to 10:90. In a preferred embodiment, the gelling agent forms approximately 0.1 - 2 wt.% of the fat composition, wherein the wt.% is based on the total weight of the fat composition.

Consequently, in a preferred embodiment, the fat composition comprises:

0.1 - 5 wt.% of the glucomannan gum, preferably konjac gum;

0.1 - 2 wt.% of a gelling agent, preferably xanthan gum;

2 - 25 wt.% of the fat, preferably olive oil;

0.01 - 5 wt.% of the coagulating agent, preferably calcium hydroxide;

45 - 93 wt.% water; wherein the wt.% is based on the total weight of the fat composition. The fat composition may further comprise 4 - 20 wt.% of a browning agent, preferably dextrin.

The fat composition of the invention may further comprise a plant or other non-animal protein, preferably in an amount of 0.5 to 5 wt.% based on the total weight of the fat composition, more preferably 1 to 3 wt.%. The plant protein serves as a binder or emulsifier for the fat/gum composition, but also provides nutrition protein to the composition. Suitable protein sources are described elsewhere herein. Preferably, the plant protein may be soy, potato, pea, fava bean or mixtures thereof.

In some embodiments, the fat component (for example, plant-based fats such as oils) can be omitted from the fat composition. Processes of the invention may therefore comprise the following steps:

(c) setting the fat composition; wherein the fat composition comprises a glucomannan gum, a coagulating agent, and water, and optionally does not contain a fat.

Meat analogues of the invention may comprise a fat composition and a protein component, wherein the fat composition comprises a glucomannan gum, a coagulating agent, and water, optionally wherein the fat composition does not comprise a fat, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

In these embodiments in which the fat is omitted from the fat composition, the fat composition may comprise: 0.1 - 5 wt.% of the glucomannan gum, preferably konjac gum;

0.1 - 2 wt.% of a gelling agent, preferably xanthan gum;

0.01 - 5 wt.% of the coagulating agent, preferably calcium hydroxide;

Alternatively, the fat composition used in the invention may comprise a fat, an alginate, a browning agent, a calcium source, and a chelating agent, such as described in UK Patent Application No. 2212131 .3 and UK Patent Application No. 2218331 .3.

Accordingly, processes of the invention may comprise:

(c) setting the fat composition; wherein the fat composition comprises a fat, an alginate, a browning agent, a calcium source, and a chelating agent.

Meat analogues of the invention may comprise a fat composition and a protein component, wherein the fat composition comprises a fat, an alginate, a browning agent, a calcium source, and a chelating agent, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

Optionally the browning agent can be omitted from the fat composition.

The fat composition may comprise: approximately 1 .5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of the browning agent; approximately 0.1 to 1 wt.% of the calcium source; approximately 0.05 to 1 wt.% of the chelating agent; and water; wherein the wt.% is based on the total weight of the fat composition.

The fat in the fat composition may comprise at least one selected from the group consisting of shea butter, rapeseed oil, canola oil, corn oil, coconut fat, rice bran oil, safflower oil, sesame oil, peanut oil, sunflower oil, linseed oil, avocado oil, grape seed oil, olive oil and palm fat, or a combination thereof. The fat in the fat composition may be an oil. The fat may comprise sunflower oil. The fat may comprise rapeseed oil. The fat may comprise olive oil.

The alginate in the fat composition is the main element responsible for setting the fat composition such that it is solid or semi-solid at room temperature, though it will be appreciated that other setting or gelling agents could be used. Alginates are naturally occurring polymers, which may be obtained from bacterial and algal sources. Alginates are commonly obtained from brown seaweed. The alginate used in the fat compositions described herein may be an alginate salt. The alginate may comprise sodium alginate, potassium alginate, or a combination thereof. Preferably, the alginate is sodium alginate.

The browning agent provides crispiness to the fat composition on cooking. In addition, the browning agent may also provide a realistic visual sensory experience while cooking, as the fat composition turns brown to resemble cooked animal fat. The browning agent is selected from the group consisting of xylose, arabinose, galactose, fructose, mannose, sucrose, dextrose, lactose, maltose and dextrin. Preferably, a dextrin is used. Dextrins can be produced from starch using enzymes like amylases, or by applying dry heat under acidic conditions. Preferably, a maize dextrin is used. The use of dextrin in particular provides sensory improvements over fat compositions known in the art, for example those using starches to provide browning.

The calcium source in the fat composition provides a source of calcium ions, which react with alginate to form a gel. The source of calcium ions in the composition may be a low solubility calcium source (otherwise known as “sparingly soluble” calcium source), such as calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, or a combination thereof. Such low-solubility calcium sources are known in the art. The calcium source may be calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, calcium chloride, calcium citrate, calcium gluconate, calcium acetate, or a combination thereof. The fat composition may comprise calcium sulphate.

The chelating agent can be any agent useful for reacting with or otherwise sequestering calcium ions. Thus, the chelating agent may be any compound that reacts with metal ions to form a stable complex. The chelating agent may comprise at least one of tetrasodium pyrophosphate (TSPP), sodium hexametaphosphate, sodium citrate, ethylenediaminetetraacetic acid (EDTA), sodium triphosphate, sodium tripolyphosphate, diphosphates, triphosphates, polyphosphates, or a combination thereof.

The chelating agent may be tetrasodium pyrophosphate (TSPP). The chelating agent may be sodium triphosphate.

In a preferred embodiment, the fat composition comprises olive oil, sodium alginate, calcium sulphate, dextrin, and tetrasodium pyrophosphate (TSPP). In a further embodiment, the fat composition comprises olive oil, sodium alginate, calcium sulphate, dextrin, tetrasodium pyrophosphate (TSPP), and water. In a further embodiment, the fat composition comprises olive oil, sodium alginate, calcium sulphate, dextrin, and sodium triphosphate. In a further embodiment, the fat composition comprises olive oil, sodium alginate, calcium sulphate, dextrin, sodium triphosphate, and water.

Thus, the fat composition may comprise: approximately 10 to 12 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

In an alternative embodiment, processes of the invention may comprise:

(c) setting the fat composition; wherein the fat composition comprises an algae or seaweed based gel.

Meat analogues of the invention may comprise a fat composition and a protein component, wherein the fat composition comprises an algae or seaweed based gel, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

Algae and seaweed based gels include hydrocolloid gels such as carrageenan, alginate, and others.

Any of the fat compositions or meat analogues described herein may further comprise cultivated fat. Cultivated fat (also described as “cultured fat” or “lab-grown fat”) refers to animal-based fat obtained through laboratory processes, such as culturing cells that can produce animal fat products. Cultivated fats may be used in the meat analogues described herein, although it will be appreciated that the fat is in fact animal fat. For the purposes of this disclosure, cultivated fat is considered to be of non-animal origin. Cultivated fat can be used in meat analogues to enhance flavour, and provides an alternative to animal fat obtained through animal agriculture. Cultivated fat can form part of the fat composition, or it can be added separately when the fat composition is mixed with the pieces of protein composition.

Protein composition The protein composition may be a fibrous protein composition. In some embodiments, the protein composition comprises a high moisture protein extrudate (HME). As used herein, the term “high moisture protein extrudate” refers to a protein source that has a solid, fibrous structure, with a plurality of aligned fibres in a same or similar orientation. The solid and fibrous structure of high moisture protein extrudate provides a realistic look and texture to the meat analogue.

As would be understood by a person of skill in the art, high moisture protein extrudate can be obtained by a process of high moisture extrusion, for example by inputting the protein source through a single ortwin barrel extruder and cooling die. High moisture extrusion (or high moisture extrusion cooking) describes a process that allows the formation of strands or larger pieces from protein rich powders, slurries or small pieces such as plant proteins, meat and fish. High-moisture extrusion of plant proteins has recently gained increasing attention for producing meat alternatives. The combination of heating and subsequent cooling of the protein-water mixture (with optional starches, colour, oil, and fibres) facilitates the texturization of the product and produces a layered or fibrous structure with a ‘meat like’ appearance. High moisture extrusion is characterised by processing materials with a high water content, compared to traditional extrusion methods. Typically, the materials used in high moisture extrusion have a water weight higher than 40% and often higher than 50%. Often, high moisture extrusion is combined with a twin screw extruder for making unconventional food products.

Alternatively, the protein composition may comprise textured (also known as texturised) vegetable protein (TVP). In contrast to high moisture protein extrudate, TVP is typically rehydrated and held together with other ingredients as a paste-like material. TVP may have fewer and shorter fibres compared to HME, said fibres running in different orientations to each other.

Alternatively, the protein composition may comprise a combination of high moisture protein extrudate and textured vegetable protein. Protein compositions described herein may also be provided using processing steps or machinery such as Source Technology and/or PowerHeater™ (Interfood) technology. Processes for producing high moisture protein extrudate and textured vegetable protein are known in the art.

HME and TVP are “set” protein compositions, i.e. they are generally firm to the touch. However, in an alternative embodiment, the protein composition may be an unset protein composition. In other words, the protein composition may comprise a protein mixture that has not yet undergone high moisture extrusion cooking or texturization. In this way, the unset fat composition can be mixed with the protein composition either before the texturization process, during the texturizing process, or after texturization.

The protein composition may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or a combination thereof. The protein composition provides the protein that would otherwise be provided by animal meat, for example from farmed animals. Plant protein refers to any protein derived from a plant source. The plant protein may be any commonly used plant protein, in particular pea protein, soy protein, wheat protein, fava bean protein, chickpea protein, oat protein, lentil protein, maize protein, mung protein, hemp protein, pumpkin protein, and combinations thereof.

The protein can be granulated or extruded and can also be hydrolysed. A plant protein isolate may also be used, such as a soy protein isolate. Protein isolate is a highly refined or purified form of protein with a minimum protein content of 90% on a moisture-free basis. In the case of soy, it may be made from defatted soy flour which has had most of the non-protein components, fats and carbohydrates removed.

The protein composition may comprise pea protein. The protein composition may comprise soy protein. The protein composition may comprise a combination of pea protein and soy protein.

As an alternative or in addition to plant protein, meat analogues as described herein may also be prepared using cultured meat protein. “Cultured meat protein” (also described as “cultivated meat protein” or “lab-grown meat”) refers to animal-based protein obtained through a process of culturing animal cells. It is noted that the use of cultured meat protein is described herein for a “meat analogue”, although it will be appreciated that the protein is in fact animal protein. For the purposes of this disclosure, cultured meat protein (or indeed any cultured animal products such as fat) is considered to be of non-animal origin. The use of cultured meat protein in a meat analogue has the potential to provide animal based protein whilst alleviating some of the ethical and environmental concerns around animal farming and associated land and water use.

Meat analogues produced according to the processes described herein may also be prepared using fermented proteins. Fermented proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). The term “fermented proteins” encompasses plant or other proteins that have been fermented through microbial anaerobic digestion, typically to improve the flavour, texture, or nutritional value of the protein. An example of a fermented protein is tempeh. Fermented proteins also encompass the use of microorganisms to produce proteins directly, for example by genetically engineering yeast cells to produce a protein of interest. In the present invention, fermented proteins may be obtained by any method known in the art.

Meat analogues produced according to the processes described herein may also be prepared using fungal proteins. Fungal proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). As used herein, the term “fungal protein” encompasses any protein produced by or derived from fungi, such as mycoprotein. The advantages of the processes described herein are not limited to those meat analogues comprising the protein sources described above. Any other protein source may be used.

The invention will now be described by reference to the following non-limiting examples.

EXAMPLES

The aim of the first experiment was to determine whether a fat composition comprising a glucomannan gum, a fat, a browning agent, a coagulating agent, and water could be used to produce a bacon rasher. The approaches tested and results are shown in Table 1 .

Table 1

As shown in the first row of Table 1 , simply vacuum sealing a rind of set fat to the edge of a protein composition to produce a bacon rasher resulted in no adhesion between the fat and the protein. Such bacon rashers fall apart immediately when handled and during cooking. Similarly, use of a plantbased edible glue resulted in only very poor adhesion between the fat and the protein.

Applying the fat composition in an unset form and leaving it to set with the protein composition improved the adhesion between the protein and the fat. However, generally, adhesion between the two components was difficult as the fibres of the protein composition were quite dry. Generally, there was low interaction between the fat composition and the plant protein fibres. Water loss was also an issue as the plant fibres did not absorb much water.

The inventors then attempted to use the fat composition in a completely different way. The inventors sought to recreate the architecture of a chicken drumstick, in which protein fibres are bound together by connective tissue with intramuscular fat. In the below experiments, shreds of high moisture protein extrudate (HME) or textured vegetable protein were combined with the fat in an unset form and mixed, then the resulting mixture was allowed to set. The results are shown in Table 2.

Table 2

Using the fat composition in an unset form and combining it with the HME or TVP shreds so as to create a continuous network of fat in the meat analogue produced surprisingly good adhesion between shreds and unexpectedly high and realistic succulence (juiciness).

Although adhesion and succulence was achieved with all conditions tested, the best overall results were obtained when the majority of the shreds of HME were neither too small (0.1cm) nor too large (5cm). Lowering the total fat content also still produced adhesion and succulence, which is advantageous for low fat food products.

Claims

1 . Process for preparing a meat analogue, comprising:

2. Meat analogue comprising a fat composition and a protein component, wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water, wherein the protein component comprises a plurality of pieces of a protein composition, and wherein the fat composition is distributed between the pieces in a substantially continuous network of the fat composition.

3. Process of claim 1 , or meat analogue of claim 2, wherein the fat composition further comprises a browning agent.

4. Process of claim 1 or 3, or meat analogue of claim 2 or 3, wherein the fat composition further comprises a gelling agent.

5. Process or meat analogue of claim 4, wherein the gelling agent is xanthan gum, agar, guar gum, or locust bean gum, preferably wherein the gelling agent is xanthan gum.

6. Process of claim 1 or 3, or meat analogue of claim 2 or 3, wherein the fat composition comprises:

0.1 - 5 wt.% of a glucomannan gum;

2 - 25 wt.% of a fat;

0.01 - 5 wt.% of a coagulating agent; and

45 - 93 wt.% water; wherein the wt.% is based on the total weight of the fat composition.

7. Process or meat analogue of claim 6, wherein the fat composition further comprises 4 - 20 wt.% of a browning agent.

8. Process or meat analogue of claim 6 or 7, wherein the fat composition further comprises 0.01 - 2 wt.% of a gelling agent.

9. Process of any of claims 1 or 3-8, or meat analogue of any of claims 2-8, wherein the network of the fat composition is an adherent network.

10. Process of any of claims 1 or 3-9, or meat analogue of any of claims 2-9, wherein the network of the fat composition is arranged to act as a binding agent.

11. Process of any one of claims 1 or 3-10, or meat analogue of any of claims 2-10, wherein the network of the fat composition is arranged to bind the pieces of the protein composition together.

12. Process of any one of claims 1 or 3-11 , or meat analogue of any of claims 2-11 , wherein the network of the fat composition is arranged to act as a connective tissue.

13. Process of any one of claims 1 or 3-12, or meat analogue of any of claims 2-12, wherein the network of the fat composition extends throughout the meat analogue in all directions.

14. Process of any one of claims 1 or 3-9, or meat analogue of any of claims 2-9, wherein the pieces of the protein composition are in the form of shreds, strands, fibres, chunks, irregular pieces, or a combination thereof.

15. Process of any one of claims 1 or 3-10, or meat analogue of any of claims 2-10, wherein at least 70% of the pieces of the protein composition are between approximately 0.2 to 15 cm in any dimension.

16. Process of any one of claims 1 or 3-11 , or meat analogue of any of claims 2-11 , wherein at least 70% of the pieces of the protein composition are between approximately 0.2 to 6 cm in any dimension.

17. Process of any one of claims 1 or 3-12, or meat analogue of any of claims 2-12, wherein at least 70% of the pieces of the protein composition are between approximately 6 to 15 cm in any dimension.

18. Process of any one of claims 1 or 3-17, or meat analogue of any of claims 2-17, wherein at least 70% of the pieces of the protein composition do not exceed 15 cm in any dimension.

19. Process of any one of claims 1 or 3-18, or meat analogue of any of claims 2-18, wherein the fat composition is present in an amount between approximately 1-40 wt.%, wherein wt.% is based on the total weight of the meat analogue.

20. Process of any one of claims 1 or 3-19, or meat analogue of any of claims 2-19, wherein the protein component is present in an amount between approximately 5-40 wt.%, wherein wt.% is based on the total weight of the meat analogue.

21. Process of any one of claims 1 or 3-20, or meat analogue of any of claims 2-20, wherein the weight ratio of the protein component to the fat composition is between about 5:1 and 1 :10.

22. Process of any one of claims 1 or 3-21 , or meat analogue of any of claims 2-21 , wherein the meat analogue is a chicken drumstick analogue, a chicken leg analogue, a chicken wing analogue, a steak analogue, a chicken analogue, a bacon analogue, a mincemeat analogue, a burger analogue, a sausage analogue, a meatball analogue, a beef analogue, a pork analogue, a lamb analogue, a sliced meat analogue, a chicken joint analogue, a pork joint analogue, a lamb joint analogue, a beef joint analogue, a roast joint analogue or a fish analogue.

23. Process of any one of claims 1 or 3-22, or meat analogue of any of claims 2-22, wherein the protein composition is a fibrous protein composition.

24. Process of any one of claims 1 or 3-23, or meat analogue of any of claims 2-23, wherein the protein composition comprises a high moisture protein extrudate.

25. Process of any one of claims 1 or 3-24, or meat analogue of any of claims 2-24, wherein the protein composition comprises textured vegetable protein.

26. Process of any one of claims 1 or 3-25, or meat analogue of any of claims 2-25, wherein the protein composition comprises one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or a combination thereof.

27. Meat analogue produced by the process of any one of claims 1 or 3-26.

28. Use of a fat composition as a substitute for connective tissue in a meat analogue, wherein the fat composition comprises a glucomannan gum, a fat, a coagulating agent, and water.

29. Process for preparing a meat analogue, comprising:

(a) combining an unset fat composition with an unset protein composition; and