KR810001481B1 - Method of manufacturing meat-stbstitude from plant protein - Google Patents

Abstract

An apparatus for producing a dense layered meat analogue from vegetable protein consists of a two-stage combination of extruders. Two extruders are set at an angle of 90oC so that the inlet of the second is positioned to receive the extruded mixture from the first. Both extruders have jackets for temp. control and mixture can be added in the barrels. Dry materials are fed to a high-speed mixer before the first-stage multi-head extrusion cooker. An extruded rope of largely unoriented mixture falls into the feed hopper of the second cooker which has an elongated hollow tubular spacer on its extrusion end.

Description

Apparatus for manufacturing a meat substitute having a regular layer of dense and untwisted from vegetable protein

1 is an elevational view of a double extrusion apparatus of the present invention.

2 is a plan view seen from the upper side of FIG.

3 is an enlarged vertical sectional view of the second extrusion cooker shown in FIGS. 1 and 2;

Figure 4 is a 9.5 times photograph of a meat substitute product carried out by the device of the present invention.

5 is a 5 times photograph comparing the side of ham and ham substitutes.

6-8 are electron micrographs taken at 19.5, 30, and 139 times the meat substitutes according to the present invention.

9-11 are enlarged (3.35X) photographs of a single piece of meat substitute based on plant protein based on the present invention, FIG. 9 is a dry substitute, FIG. 10 is a hydrated form, Figure 11 shows the same layer as the actual meat, separated by hand.

Figures 12-14 show enlarged (3.35X) photographs of different meat substitutes, each showing a dry form, a hydrated form, and a layer after separation by hand.

The present invention is used in the manufacturing method of extruded meat substitutes based on vegetable protein having a meaty appearance and functionality suitable for use in foods such as soups, curry, stew, pot pie, sauce, canned food Relates to a device. In particular, meat substitutes having the same layer structure as meat are made of vegetable protein and water, such as horses, which are degreased under conditions that minimize the extent of expansion occurring during extrusion of the product. It is about.

As the world's population grows, so does the need for edible protein, which has become nutritionally important. As a result, the tendency to use vegetable protein sources for food rather than meat protein is increasing. It is more effective for humans to consume the equivalent amount of protein in the vegetable state than when using the meat after raising the animal to feed the animal. For example, calf needs 1,350 pounds of meat to feed 3,175 grams (7 pounds) of high protein feed, so conversion is ineffective. Therefore, development of economical and commercial methods and devices for processing vegetable proteins such as soybeans in an excellent form for human consumption is currently underway.

Many researchers in the art have attempted to develop methods and apparatus for producing suitable meat products from vegetable protein sources. It has been found that in most cases degreasing soybean powder or other vegetable proteins can be extruded to organize and orient vegetable proteins to produce meat additives for hamburgers or other products. Examples of such methods and apparatus include US Pat. Nos. 3,047,395, 3,142,571, 3,488,770, and 3,870,805. Although such extrusion methods and apparatuses are to some extent suitable in the art, meat substitute products prepared therefrom have various properties that are subject to many application restrictions as complete substitutes for meat. That is, one of the disadvantages of the conventional products is that they have the property of expanded cellular sponge form. In particular, most of these meat additives are prepared in an extruder under high pressure and temperature conditions, resulting in a twisted and twist oriented meat additive, which is characterized by the chewy structure of the twisted layer after rehydration, The range of uses of meat substitutes is limited. This limits the use of the product to substitutes for meat additives such as hamburgers. In addition, if too many conventional vegetable protein products are used in the form of hamburger meat, the added meat becomes an undesired sponge form and has an unsightly appearance and tastes bad.

Usually, products extruded by conventional manufacturing equipment are twisted and in the form of cells, which tends to crumble when using agglomerated products as complete meat substitutes. However, preferred lump products have special uses such as stew, sukiyaki and the like, while conventional crumbled vegetable protein products cannot be used for these foods. Some chunk-sized vegetable protein meat substitutes require similar texture to real meats, but do not mix well with real meats, as in the case of products with added chunks, so that some inadequate properties are more severe.

Apparatuses for use in other methods for the preparation of meat substitutes based on vegetable proteins have been proposed, but these methods and apparatuses also face many of these unresolved problems. For example, a so-called "spun filament" method is used, which recovers and stretches filaments obtained by pulling very thin strings or filaments of separated proteins into yarns, fats, egg proteins, binders, dyes, Mix with fragrances and combine under pressure to make a complete meat substitute. Such spun products are superior to meat additives extruded by conventional manufacturing equipment. However, the high cost of production and complexity of processing eliminates many of the advantages of using vegetable protein meat substitutes, such as the use of inexpensive vegetable protein instead of more expensive meat.

Therefore, the most important object of the present invention is a dense, relatively uniform layer, has an untwisted structure, exhibits taste, appearance, and functionality similar to actual meat, and is a substitute for a wide range of meats such as beef, pork or fish. To provide a meat substitute based on the extruded vegetable protein that can be used as.

It is also an object of the present invention to produce a low cost extrusion process of meat substitutes exhibiting the desired texture and appearance of vegetable protein products as described above using relatively inexpensive sources without extracting filaments or other complex devices and processes. To provide.

Another object of the present invention is to heat and stir a mixture of vegetable protein and water to make a hot, fluid and unmixed mixture, which is then placed on an extruded end of a long processing chamber to form a layer in the product prior to extrusion. An extrusion cooker having a tubular extension is provided to provide an extrusion cooker for producing a layered and untwisted meat substitute. In the extruder barrel during processing, the mixture is subjected to displacement forces axially and transversely relative to the barb, while within the tubular extension the mixture is axially displaced and the dense real meat in a layer of meat substitutes. It helps to build a structure like In addition, processing conditions such as pressure and temperature in the final and extension parts of the extruder barrel maintain the product in a relatively dense, unexpanded form and at a level where the iceberg of the vapors is invisible.

It is another object of the present invention that the first extrusion cooker is configured to allow heating, denaturation and sufficient mixing so that the organization or orientation of the protein in the mixture of vegetable protein and water does not occur and the separate adjacent second extrusion cooker is not pretreated. Unrefined protein mixture was installed to produce a dense, layered and untwisted, real meat-like product as expected of the present invention, and a second extruder was used to create a long meat-like structure for layering meat substitutes. Provided is an apparatus for use in a method of manufacturing a meat substitute that includes an extension on an extrusion end that provides a process chamber and the conditions in the second extruder maintain levels to ensure that the extruded product is dense and unexpanded.

The present invention will be described in detail with reference to the accompanying drawings.

Suitable dual extrusion apparatuses used in the apparatus of the present invention are described in FIGS. 1 and 2. That is, the first extruder 10, the adjacent second extruder 12, the rotary blade cutter 14, and the conventional food drying cooler 16 are included. As shown in detail in FIG. 2, the second extruder 12 is located in a vertical relationship with the first extruder adjacent to the delivery end of the first extruder 10 and emerges from the second extruder 12 to provide a dry cooler 16. A conveyor 18 was installed to deliver the workpieces entering the furnace.

In addition, the first extruder 10 described in the drawing used a Wenger model X-25 extruder equipped with an upright open top hopper 20 located on the body of the extruder to receive the dry components to be treated. . The discharge pipe 22 extends from the bottom of the hopper 20 to the long, high speed mixing cylinder 24 and the vapor and water piping (not shown) is attached to the cylinder 24 to produce a desired amount of mixing. Serves to selectively transport moisture and increase the temperature of the dry ingredients from the hopper 20. The conveying structure 26 is connected to the bottom of the cylinder 24 and extends between the bottom of the cylinder and an extruded barrel with a number of long heads. Barrel 28, for example, is arranged in seven axes of equal diameter with a peripheral jacket for the introduction of heating or cooling media, such as steam or cooling water, which is necessary to control the temperature of the mixture passing through each section of barrel 28. And consisted of a tubular head 30 interconnected. Each head 30 is configured as described and a fluid delivery and discharge conduit 32 is provided and a vapor or water inlet is provided in the barrel 28 to allow the addition of moisture directly to the flow mixture as needed.

The seventh and final head 30a of the barrel 28 is terminated in the die plate 36 having a series of die holes (see FIG. 1) so that the product introduced into the rear end of the barrel 28 The barrel 28 can be extruded out of the front end in the axial direction. For example, four dies of equally spaced die openings may be provided, but other arrangements of extrusion dies may be used.

A long multi-helical auger screw 38 is located in the barrel 28 to pass the product through the barrel 28 under conditions of mechanical cutting, stirring and pressure. In this case the auger screw 38 is made of a plurality of axes interconnected extending over the entire length of the divided barrel 28. The motive force for the extruder 10 is provided by the use of a large electric motor 39 coupled to the auger screw 38 in the barrel 28 through conventional autonomy in order to achieve axial rotation at the desired rotational speed. In this case, a control console 40 is provided to exchange heat as well as the rotational speed of the screw 38 as well as the moisture delivered to the mixing cylinder 24 and the extruder barrel 28 and the respective jackets in the barrel 28. The operating conditions of the extruder 10, including the type and amount of media, are selectively controlled and adjusted.

The second extruder 12 is usually similar to the extruder 10 and is formed of an interconnected tubular head 44 arranged in an individually jacketed shaft (see FIG. 3) for the introduction of heat exchange media such as steam or cooling water. A partial barrel 42 is included. In addition, the auger screw 46 is located in the barrel 42 and is driven by the conventional electric motor 48 and the transmission structure 50. The rear head 44b includes an upright product heater 54 which serves to deliver the pretreated product from the extruder 10 to the inner surface of the barrel 42. The nine heads 44 of the first barrel 42 were equipped with ribs with a constant diameter and steel wires arranged at regular intervals along the axis thereof. However, the inner surface of the end head 44b of the barrel 42 is slightly tapered as illustrated at 56 in FIG. 3 and these nine heads 44 have auger screwed into the portion of the first barrel 42. It accommodates a conical screw 58 in a similar arrangement coupled with the remaining portion of. Of course, the particular arrangement of barrel parts does not limit the present invention and, for example, a spiral rib or a final head arranged in a cylindrical shape may be used. In the case of the extruder 12, each head 44 of the barrel 42 is divided into fluid conduits 60, 62 for transferring and returning heat exchange medium, such as water or steam, to each head.

The extension end of the barrel 42 includes a tubular extension 64 connected in an elongated axis, which extension is connected to the remaining extruder barrel through the front opening of the head 44b. In this case, the extension 64 is 15.24 cm (6 inches) long and has an inner diameter of 11.09 cm (4.365 inches), so that a proportion of its length and diameter is provided at a ratio of about 1.37. In particular according to FIG. 3 the extension 64 is attached to the shortest end 44b of each head 44 and the head part 44b is a tubular extension 64 without the product coming from the barrel 42 being disturbed. Was arranged to pass through. The end of the tubular extension 64 mounted on the end 44b of the barrel 42 away from the hopper 54 has a die opening (24, 3/8 square inches) formed around the inner diameter of a total of 156.74 cm 2 ( It is covered by the molded plate 66 with 68). The retaining ring 70 was used to squeeze the plate 66 to the end of the extension 64 and additionally formed in the form of a single bullet structure 72 of the forming plate 66. Attached to the inner surface to guide the flow of the material entering the die opening in the tubular extension (64). The blte structure 72 includes a cylindrical portion 74 attached to the forming plate 66 and extending from the plate 66 to the back side and extending toward the back side of the left vertebra 76 having the tip 78. do.

The blade cutter 14 includes a drive motor 80 coupled to the long rotating shaft 82 as a conventional device and supported by a conventional support structure 84. The cutting head 86 includes a blade device 88 attached to the end of the shaft 82 extending from the motor 80 and positioned adjacent to the die opening 68 provided in the forming plate 66. The blade device 88 rotates during operation of the extruder 12 so that when the meat substitute is extruded from the die opening 68 the product is cut into small chunks as shown at 90 in FIG.

The conveyor 18 includes an endless belt 92 and a spout outlet 94 at the distal end of the conveyor for carrying the mass product onto the belt 92. The outlet 94 extends the belt 92 to the top of the dryer 16 where a large amount of moisture is removed from the meat substitutes, which then moves the belt 96 to a cutting spot (not shown). Throughout the collection and packaging are sent for.

The practice using the device of the present invention is to heat and stir a mixture of vegetable protein and moisture, such as degreased soybean powder (in an extruder or high speed mixer) to make it hot, fluid but not oriented without tissue formation and then the mixture. While running through the long treatment zone under moderate pressure, high levels of cutting, compression and mechanical agitation and draining the mixture in the axial direction and in both transverse directions thereof against the zone, followed by long treatment of the mixture Injecting into the site, the drainage force is applied in the axial direction to form a layered product of a meat-like structure. The temperature and pressure conditions in the treatment zone and site are then maintained at levels that allow the mixture to form layers in the mixture as it moves continuously through the treatment zone. The mixture is extruded from the treatment zone under a pressure of about 5-80 p.s.i.g. (particularly 5-65 p.s.i.g) to minimize the expansion range of the product. In a suitable form the product is extruded at a pressure of 15-45 p.s.i.g. at 100 ° -320 ° F. (especially 150-250 ° F.).

In more detail with the use of the device of the present invention, 20-55% by weight of vegetable protein and water taken from soybean, wheat, corn, cottonseed, rapeseed, peanut, sesame, sunflower, and protein mixtures thereof (particularly 30 -45%) of the mixture. The moisture content used above refers to the total moisture present, ie the natural and added moisture in the plant protein source. In particular, for the preparation of mixtures, most of the powdered skim, gluten flour, corn gluten, skim cottonseed powder, vegetable concentrates, vegetable isolates, peanut powder, sesame powder, sunflower powder and protein sources taken from the mixture are prepared. It is preferable to use.

In any case, the mixture is first injected and passed through a first extruder (eg extruder 10 in Figs. 1-2) under conditions of pressure above atmospheric pressure, extrusion stirring and shear, and then the product is hot, fluid and oriented. Unextruded and undried at a temperature of about 100-250 ° F. and pressure of 9-95 p.sig (particularly 40-80 p.sig).

Referring to FIGS. 1 and 2 where the Wenger Model X-25 extruder was used as the first extruder 10, the first stage treatment of the vegetable protein-moisture mixture was about 150-400 r.pm (particularly 200-300 r.pm). By using an auger rotational speed where the mixture is extruded from the first extruder under a pressure of 40-80 p.slg without being oriented. The temperature and pressure conditions are maintained by selectively introducing the cooling or cooling water of each head of the ejector barrel. The protein-moisture mixture is most suitably extruded as a hot, fluid and thermoplastic rope, without cutting or sapling as shown at 100 in FIG. This demonstrates that the product has been thoroughly mixed and fundamentally denatured, but it does not exhibit the degree of orientation or weaving that inhibits the formation of layered meat substitutes in the second extruder.

The apparatus of the present invention is to treat the hot and flowable mixture in a second extruder of the type shown in the figure in the second step. In particular, the mixture passes through the barrel of the extruder under conditions of compression, stirring and shear at pressures above atmospheric pressure and relatively high levels of temperature. In the illustrated embodiment the auger speed is suitably at a level of about 100-350r.pm (particularly 200-300r.pm) and the screw speed is varied with the extruder of the type described above, e.g. Wenger Model X-200 Large industrial equipment is usually operated at slightly lower screw speeds than for smaller capacity extruders. Rotation of the center screw stretches the vegetable protein while simultaneously allowing the mixture to be continuously injected through the long extension attached to the delivery end of the barrel. Final extrusion takes place by the axis of the extrusion barrel, even with a die having holes arranged around it. As illustrated in FIG. 3, an induction device of the mixture in the form of a blette or other suitable device is arranged in the extension to direct the flow of the mixture in the extension toward the die opening.

The final step using the device of the present invention is to cut the excess moisture by cutting it into chunks of the desired size when the layered and untwisted workpiece emerges from the second extruder.

The product implemented using the apparatus of the present invention will be described with reference to FIGS. 4-14. First, Figure 4 is an enlarged photograph of a chunk of meat substitutes. In this case, the surrogate was treated for 110 minutes at 15 p.s.l.g. In addition, the layers are not twisted together and can be separated similarly to cuts in chunks of meat such as ham or beef steak.

5 illustrates a comparison between a real ham cooked and a similar product such as ham made red by the practice of the present invention. When the fork is separated to structurally compare the layers of the two products, the appearance of the ham and the substitute is almost the same, and in fact, it is almost impossible to distinguish between the natural ham and the substitute performed by the device of the present invention.

6-8 are enlarged electron scanning micrographs of a single piece of a substitute such as ham obtained by the practice of the present invention. This picture is taken along the shear plane cut vertically in the extrusion direction. The study of the cross-sectional photographs explains that the layers and denseness appear in the product, giving them the same appearance, texture and taste as real meat.

Figures 9-11 and 12-14 are photographs taken after drying and by hand separation of the layers in dry, boiling water, respectively, illustrating a single operation of the product carried out by the device of the present invention. These two types of pictures illustrate the actual meat of the product.

Full load of the second extruder 12, shown in FIGS. 1-2, to form a meat-like layer in the product with the product implemented using the apparatus of the present invention, that is, the mixture is When stopped when filled in the extension, a sample of the mixture taken from the extruder barrel and another sample taken from the extension was observed. The mixture at the inlet was not layered and the mixture at the extension inlet was slightly along the plane perpendicular to the flow direction. The long sheet structure layer was shown. This sheet was relatively short, but formed a layered structure. In addition, it was not visually discernible that the sheet forming effect occurred in the cylindrical wall of the extension. However, when the mixture moves along the flow line between the extruder barrel and the die openings arranged around it, there is an effect of forming a long thin layer parallel to the longitudinal axis of the extension.

Based on the above effects, the following treatment theory can be expected. First, in the second extruder barrel, the protein and water mixture are subjected to shearing action due to pressure, stirring and rotation of the spiral auger above atmospheric pressure. Such a rotator displaces the mixture axially and transversely relative to the barrel so that the vegetable protein is properly diffused in the mixture, which is believed to be essential to orient the protein to the final product.

In some cases, only pressure acts on the mixture as the mixture continuously leaves the extruder barrel and passes through the elongate section.

This pressure is derived from the axial (auger screw axis) displacement forces exerted on the mixture by the augers in the extruder barrel. The displacement force acting on the mixture in the extension is therefore exerted by the extruder barrel and the above axis relative to the extension. Of course, this displacement force in the extension is due to the following three factors: firstly, the mixture leaving the extruder barrel is elastic and therefore part of the cross-channel force given to the mixture in the barrel. And temperature effect Third, it is not only the influence of the pure axis since it is caused by any cross- narrowing momentum in the mixture transmitted from the movement of the screw.

It is believed that the axial displacement of the mixture in the extension, depending on the temperature and pressure conditions maintained, passes through the die openings arranged around in a tubular stream line. This effect is similar to the fluid flow pattern, where the fluid is sheared. In this case the mixture at the wall of the die opening has theoretically no velocity while the mixture at the center of the die opening has maximum velocity. As a result, shear forces occur between the different cylindrical “flow tubes” of the flow so that some of the mixture in the extension passes at different rates.

This relative speed difference effectively shears the protein and the attraction of the protein between adjacent tubular “flow tubes” as the mixture advances along the length of the extension. Moreover, such attraction cannot easily be reestablished because relatively low temperature conditions are maintained within the extension. Conversely, protein molecules that pass through a given tubular “flow tube” have a strong binding force, facilitating layer formation. Thus increasing the structural identity of each layer despite the fact that no actual mixing takes place between adjacent layers of the flow. The filling of the mixture is also at a relatively low temperature so that the protein therein can be stretched and oriented as it flows through each “flow tube”.

On a tube layer or on a “flow tube” through which material flows, it can be said to be the same as a central cylinder passing at a different speed than the cylindrical axis coinciding with the centerline of the spacer. The different velocities of the layers arise from the “boundary effect” in the wall of the spacer. The high velocity of the thermoplastic water, which has a relatively low velocity, causes its flow in the spacer.

Another factor considered that the unique product using the device of the present invention is important for implementation is that there are no practical limitations as the mixture passes from the extruder barrel into the long extension. It is believed that this is offset by the practical limitation at the inlet of the extension, i.e. the shape of the flow, which decreases the velocity of the cross section (e.g. by die plate) in the mixture as the mixture moves from the auger forward to the die opening. . This device is important for obtaining products with layers in which the layers are not intertwined. In conclusion, it is believed that the position of the die opening relative to the outer major surface of the die plate is most characteristic, and the installation of the blits described in FIG. 3 causes the product to be layered. This is because the moving tube flow tube is prevented from moving toward the center of the extension and is led to the outer opening of the die plate.

In any case, it is clear that the meat substitute obtained by the practice using the apparatus of the present invention can provide a meat substitute which is layered and kinked as in the attached photograph.

Claims (1)

The final head end 30a connects the first extruder 10 by means of a product wave 54 for heating and stirring the mixture in a flowable and unoriented state in a die plate 36 having a series of die holes. The bollet structure 72 is mounted on the inner diameter of the tubular extension portion 64 connected to the final head end 44b of the second extruder 12, but the die opening 68 holds the forming plate 66. Apparatus for producing a meat substitute having a regular layer of dense, untwisted from the vegetable protein, characterized in that it is configured by landing.

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