RU2544913C2 - Method for production of modified food additive based on gluten - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: native gluten is introduced into the technological treatment zone located directly in the twin screw extruder chamber. Gluten is moistened till moisture content is equal to 35-45% by way of water/water steam introduction into the chamber, subjected to extrusion treatment during 30-50 sec at the screw rotation rate equal to 350 rpm under a pressure of 50-70 atm. Heating lasts 30-50 sec till the treatment temperature is equal to 160°C. Specific mechanical energy is within the range of 380-410 kJ/kg. Treated native gluten is replaced from the technological treatment zone into the matrix. The produced protein mass is forced through 3 mm diameter matrix drawing die holes. The releasing texturate rope is cut into granules, cooled and dried.

EFFECT: target product quality enhancement, raw materials biological and nutritive value preservation at a high level, pathogenic microflora suppression and manufacture of a product with preset indices and high protein content in the texturate.

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Description

The invention relates to the food industry, namely to protein concentrates and methods for their production from sources of plant origin, intended for use in various sectors of the economy: food (meat, dairy, canning, baking, pasta, confectionery, food-concentrate industries), feed industry in the production of feed and other manufacturing industries.

In particular, the invention relates to the food industry to a method of creating a new type of textured food supplement based on gluten obtained by extrusion processing, aimed at enriching meat products with a vegetable protein component and improving their functional and technological properties.

Currently, the most common grain crops in Russia are: wheat, rye, barley, oats, corn, triticale. Cereal crops provide about 50% of the energy and give half of the protein produced by humans, consumed by the average inhabitant of the planet. When wheat and other cereals are processed into starch, large amounts of cheap protein are generated as waste. Despite the low functional and technological properties of these proteins (solubility, rheological characteristics, hardness, emulsifying ability, etc.), valuable products containing protein - gluten and protein concentrates - are obtained from cereal seeds. The prospects for using cereal protein in food technology are obvious, especially in regions that specialize in growing specific cereal crops.

Meat and meat products are one of the main products of animal origin in the human diet, which contain irreplaceable high-grade proteins, fats, vitamins, minerals and other vital nutrients. Thus, most of the necessary components can be obtained from products of animal origin.

In the modern food industry, various methods of improving the quality of food products and the improvement of the technological process are used. The use of food additives turned out to be the most cost-effective and easily applicable, as a result of which food additives are widely used in most countries of the world.

The main objectives of the introduction of food additives include:

1. improving the technology of preparation and processing of food raw materials, manufacturing, packaging, transportation and storage of food. The additives used in this case should not mask the consequences of using poor-quality or damaged raw materials or carrying out technological operations in unsanitary conditions;

2. preservation of the natural qualities of the food product;

3. improving the organoleptic properties or structure of food products and increasing their stability during storage.

The question of the use of food additives in food products is inextricably linked with the study of their toxicity, which is usually understood as the ability of substances to harm the body. At the same time, any chemical substance under certain conditions can be toxic, with a mutating effect. Therefore, it is appropriate to talk about harmlessness, which should be understood not only as the absence of any toxic manifestations, but also as the absence of a long-term consequence: carcinogenic and carcinogenic properties (the ability to cause the development of malignant tumors), as well as mutational, teratogenic, gonadotoxic (the ability to cause mutations, deformities ) and other properties that affect offspring.

When developing the invention, the above factors were taken into account, which led us to conclude that the use of gluten is promising, since it does not harm human health, meets the above requirements for food additives, and is a cheap waste of domestic production of wheat.

Also, when developing the invention, it was taken into account that extrusion processing is one of the most promising and highly efficient processes that combines thermo-hydro and mechanical processing of raw materials, which allows to obtain new generation products and components with desired properties, with a new structure.

Extrusion processing can provide several advantages over traditional technologies.

The possibilities for the homogenization of raw materials and their heat treatment incorporated in the extrusion method make it possible to solve the most important problems related to the quality of products: preservation of biological and nutritional value, suppression of the development of pathogenic microflora, the formation of predetermined structural and mechanical properties and organoleptic characteristics.

Extrusion technology can be classified as multifunctional processes that allow for continuous production, mixing and moisture treatment, sterilization, extrusion, molding and granulation, as well as to obtain products with adjustable properties, varying the composition and processing parameters of raw materials.

In the source of information ("Preparation of soy protein Concentrate and isolate from extruded-expelled Soybean Meals", by H. Wang, L, Al Johnson and T. Wang in "Journal of the American Oil Chemists Society", 2004, 81 (7) , 713-717 [1]) describes a new approach to the production of protein concentrates, based on the use of traditional methods of extraction of plant materials, pre-processed by extrusion-expeller method of processing plant sources of raw materials. Such pretreatment was carried out at a temperature of 135-140 ° C, a pressure of 20-50 atm, a moisture source of raw materials not exceeding 10-12%, for 15-30 s. It should be emphasized that the so-called process of dry extrusion of raw material sources without any additional moisture is used here, proceeding when the moisture content does not exceed, as a rule, 10%. It should be emphasized that this method of processing raw material sources is very far from the traditional classical extrusion process to obtain high-quality textured protein products that mimic the structure of meat tissue products of a layered, lamellar finely porous structure. These raw material processing conditions allowed us to regulate and preserve a certain part of the proteins in an undenatured state, provided cell walls to break and facilitated the flow of oil contained in them during subsequent pressing, and significantly suppressed the activity of antinutrients present in the raw materials, such as trypsin and urease inhibitors, whose activity decreased to values of 0.1-0.2 pH units. Using the traditional extraction methods described above to the sources of raw materials processed by the method described in this invention, it was possible to obtain products similar in chemical composition and functional properties to products obtained from standard sources of raw materials.

This method of production of protein concentrates is of undoubted scientific and practical interest, expanding the range of raw materials due to the possibility of using fatty native or semi-fat-free leguminous raw materials, but, unfortunately, it cannot always provide an economically viable yield of the target product and the required level of its quality. In particular, the proposed method does not provide a level of lipid content in the final product, the proportion of which can reach values of more than 20%. Such products are known to be susceptible to oxidative damage during storage. In view of the desire to maximize the preservation of the nativeness of the composite organelles of the raw materials in which the main reserve proteins are contained, this method also has a set of all the disadvantages of other methods for the production of protein concentrates described above, due to the mechanism of diffusion extraction processes.

The invention claimed by the authors is aimed at overcoming the aforementioned disadvantages, such as unintentional input of information, unauthorized access by an unauthorized person, while maintaining portability and small dimensions of the devices and the convenience of the operation.

Also known from the prior art (WO 2009/003721 A1, 08/01/2009 [2]) an invention intended for use in the food industry, and for obtaining an extruded food product containing from about 25% to about 77% meat and / or vegetable protein. The method involves the continuous introduction into the extruder of the components of a food product, including meat and / or vegetable protein, mixing them in an extruder to obtain a mixture, heating the mixture in an extruder, extruding the food product through the forming head and cooling the food product. The product may further contain plasticizers and substantially free of cross-linking compounds. The extruder has a high ratio of “length: diameter” and contains a number of cylinders, double screws rotating around them along parallel axes and heating devices mounted on the cylinders. The group of inventions provides a product that is an analogue or substitute for meat and has a characteristic fibrous, textured appearance.

Also known from the prior art (US 6379738 B1, 04/30/2002 [3]) A method for producing an emulsion comprising protein and fat, which consists in grinding and heating the meat emulsion to a temperature of at least 132 ° C, exposing the meat emulsion to a pressure of at least 689 kPa (100 psi) to form a base consisting at least partially of a plurality of fiber-like structural formations formed into a single mass. The meat emulsion product includes a base consisting, at least in part, of a multitude of fibrous structural formations formed into a single mass containing at least 29% wt. protein and not more than 7% wt. fat. The invention allows to obtain products in appearance as close as possible to meat.

Closest to the claimed method is (US 5097017, Konwinski, Arthur N. [4]) "The process of manufacturing soy protein concentrate." This method of soybean concentrate production is not aimed at directly, but at indirectly intensifying the process of its production by solving an extremely complex problem - the presence of a large proportion of finely ground petal fragments in the raw material, a powdery material or even a finely divided dust fraction obtained during the production of a white petal, the content which in some raw materials reaches 30% -50%. The fact is that the use of such unfractionated raw materials in the traditional method of concentrate production by countercurrent submersible or percolation extraction with aqueous solutions of alcohols reduces the extraction efficiency by clogging the holes in the bottoms of the extraction devices of the fractions, their deposits on the inner surfaces of the bodies of the extraction devices, and due to sedimentation and deposition of these fine fractions on the surfaces of the heating elements decreases the heat transfer efficiency, thereby reducing the overall production clusive production process. This phenomenon also necessitates frequent stops of the entire line, unscheduled cleaning, which also dramatically reduces productivity and increases maintenance costs. One of the solutions is the separation of the fine fraction of raw materials on a standard American sieve No. 25, which, however, reduces the amount of raw materials for the production of concentrate, and also requires the search for other directions for using the separated fine fraction.

The essence of the method of production of protein concentrates described in the closest analogue is as follows. A finely ground source of raw materials is mixed with water and steam until the final moisture content of the mass is from 18% to 30%, mainly 20-25%, and extruded in twin-screw type extruder devices or single-screw extruders-expanders, which are modified by removing end matrices to ensure free mass exit, subjected to moisture treatment at temperatures not exceeding 151.1 ° C, and to prevent the creation of additional pressure and the occurrence of shear deformations in the end output part of the devices. As a result of this treatment, agglomeration of the particles of the feedstock into a continuous test mass of the macroporous structure and partial denaturation of the proteins of the feedstock, which, however, is accompanied by a slight change in the internal structure of the feed particles included in the agglomerate, are achieved. This is evidenced by the microphotographs of the feedstock and agglomerated product presented in the patent, data on the change in the NSI index of the product, which varies from initial values of 50-80 units to values of 25-45 units after its processing, and the enzymatic activity of the urease enzyme, which varies slightly as a result of the processing modes used in the invention. According to the author of the described invention, the method proposed by him is a unique process intermediate between that used for the production of compacted granular products from a fat petal on an extruder-expander and textured products from nonfat raw materials - highly porous, layered, imitating the structure of meat tissue of products manufactured on twin-screw extruders . As is known, the PDI index of 18-20 units is characteristic of these products, and the urease activity is less than 0.01 units. This is also evidenced by a comparison of microphotographs of histological sections of products shown in the patent using light microscopy obtained by implementing various extrusion modes (agglomeration, extruder-expander and twin-screw extrusion). For traditional classical extrusion of obtaining textured protein products in extruder screw devices or extruder-expanders, as you know, a prerequisite for the production of high-quality textured products is the presence of restrictive matrices in the end zone of the equipment, which prevent the free exit of the processed mass and ensure the creation of these end zones of these devices significant pressures and high shear deformation effects. It is these processing conditions that provide the product with a layered, lamellar finely porous structure. In the case of obtaining large-sized pieces of agglomerated protein concentrates from modified extrusion devices, they are, if necessary, crushed in a wet and hot state in cutting devices of the Komitrol type to achieve the optimal size of the formed agglomerate granules corresponding to the size of a standard American sieve No. 4 (mesh size 0.187 inches ) With this grinding, the fraction of small particles that impede the subsequent extraction does not exceed, as a rule, 5%, which does not cause a strong effect on the subsequent extraction process. The obtained granules of agglomerated material are extracted with aqueous solutions of alcohols. The optimal extraction conditions for the obtained particles are: a range of alcohol concentrations in water of 60-70% and an extraction medium temperature of 125-165 ° F (51.7-73.9 ° C).

The main disadvantages of the described method for producing protein concentrates include the traditional for all the above methods, the preservation of the structure of the organelles of the feedstock, and hence the traditional extraction mechanism, based on slow diffusion processes of the solvent and extracted substances. This leads to the impossibility of achieving the completeness of extraction of extractive substances of raw materials in real time the implementation of the extraction process and the use of the relatively narrow concentration range of solvent concentrations given above. Due to the presence of a relatively high proportion of undenatured proteins, the use of lower concentrations of alcohols in solution will lead to significant loss of protein in the extractant. In addition, for the described invention, it is most advantageous and advisable to use only the fat-free fine fraction of raw material obtained by extraction with organic solvents. Using the entire petal volume is inefficient as a result of increased processing costs and the absence of any additional positive effect. This circumstance significantly narrows the raw material base for the implementation of the described method for the production of protein concentrates.

To date, there has been no production of textured gluten-based products. Prior to this, it was not considered as an additive capable of not only improving the structure of the product, but also increasing its biological value due to the high percentage of protein content in gluten of more than 70%. Therefore, we can assume that the resulting gluten texturate can also act as a substitute for raw meat in the recipe, and this will not lead to a deterioration in the quality of the product.

The technical result of the claimed invention is to improve the quality of the target product, maintaining a high level of biological and nutritional value of raw materials, suppressing pathogenic microflora and obtaining a product with specified parameters and a high protein content in dough.

The problem is solved as follows.

A method of manufacturing a modified gluten-based food additive is characterized in that native gluten is introduced into the processing zone located directly in the chamber of the twin-screw extruder, where it is moistened up to 35-45% by introducing water / water vapor into this chamber, and also subjected to continuous extrusion processing for 30-50 s, at a screw rotation speed of 300-350 rpm and a pressure of 50-70 atm (5-7 MPa), while heating it for 30-50 s to a processing temperature of 155-165 ° C and with specific mechanical energy within 380 -410 kJ / kg, then the processed native gluten is transferred from the processing zone to the matrix and then, the resulting protein mass is pressed through the rotating screws through the holes of the die of the matrix - 3 mm, then the outgoing tow of texture is cut into granules and then they are cooled and drying.

In one embodiment of the invention, when native gluten is introduced into the processing zone, it is moistened up to 40%, at a screw speed of 350 rpm and a pressure of 58 atm, and heated to a temperature of 160 ° C.

Also, in one embodiment of the invention, the initial moisture content of native gluten before entering the processing zone is 10%.

Extrusion with the above set of characteristics allows you to qualitatively and quantitatively change the structure, composition and nutritional value of native gluten in protein texturate.

During thermoplastic extrusion, highly concentrated aqueous suspensions of the protein are machined at high temperatures. In this case, there is an interaction between the amino groups and the carboxyl side groups of the protein, leading to the adhesion of the polypeptide chains, as well as the interaction between lysine groups and sugar carbonyl groups (Maillard reaction). As a result, the total loss of bioavailable lysine residues reaches 30% or more.

Molecules of starch undergo maximum destruction during the exit from the extruder. As a result of processing in extruders, the starch content sharply decreases with a corresponding increase in the content of water-soluble sugars and dextrins, and the starch attackability with glucoamylase improves, which ensures high nutritional value of the products.

Vitamins, for the most part, are thermally unstable substances. It was established that the shelf life of vitamins B1, B6, B12 and folic acid increased with a decrease in the duration of processing of raw materials and an increase in its moisture content. With an increase in the diameter of the holes, the preservation of vitamin B1 increases, and the diameter of the matrices does not affect the content of vitamin B2.

In the process of developing a technical solution, it was found that for all temperature conditions at the same temperature with an increase in the speed of rotation of the screw within the studied ranges, an increase in the explosivity coefficient occurs. The most acceptable values of the coefficient of explosiveness are achieved with extrusion processing parameters - a temperature of 160 ° C and a screw rotation speed of 350 rpm.

The value of the specific mechanical energy of 380-410 kJ / kg during the extrusion process affects the moisture absorption capacity of the resulting textured gluten and reaches a maximum value of 450-510% at these rates.

The indicated specific mechanical energy data are established by wetting the processed gluten in the extruder within 35-45%. In this case, by controlling the moisture content of gluten, a variation in the rheology of the processed raw material (dynamic viscosity) is achieved.

With these parameters, an increase in the product diameter, explosive coefficient and a decrease in cutting work, shear tension, bulk density in relation to lower temperature conditions (150-155 ° C) and lower screw speeds (250, 300 rpm) are observed. See table 1.

Table 1 - Change in the structural and mechanical properties of extrusion products depending on the temperature and speed of rotation of the screw.

Changes in the structural and mechanical properties of extrusion products occur depending on the temperature and speed of rotation of the screw.

The possibility of implementing a sustainable process is also determined by such factors as the diameter of the die hole, the average size and concentration of particles of the dispersed phase, as well as their size distribution. Obviously, the average size of the dispersed particles should be significantly smaller than the diameter of the hole. Otherwise, the hole will clog. The likelihood of clogging of holes, and therefore, fiber breakage increases with increasing concentration of the dispersed phase (protein material), as this increases the likelihood of agglomerates of dispersed particles with sizes exceeding the diameter of the hole. In our case, with the signs characterizing the method specified in claim 1, the optimum diameter of the die is 3 mm. It significantly affects the textured product. Texturing of the product is carried out through narrow holes in a matrix with a diameter of 3.0 mm, followed by cutting the product with an end rotating knife of a cutting device to obtain the maximum particle diameter of the particles emerging from the extruder, not exceeding 3-5 mm, which can be directly transferred to the extraction without preliminary drying devices or for the purpose of their accumulation or long-term storage to be dried and used at the stage of extraction in dry form. The proposed method for the production of protein concentrates can be implemented in the production of large-sized forms of extrusion products, usually used in the production of special products (the basis of the so-called analogues of meat products or large-sized products such as goulash, or meatballs, or schnitzels) after additional grinding of the obtained pieces of textured products to the indicated optimal sizes not exceeding 3-5 mm across.

The essence of the method is as follows.

Native gluten with a moisture content of 10% is mixed with water and steam to a final moisture content of 35-45%, introduced into the chamber of the processing zone, which is located directly in the twin-screw extruder, and extruded at a screw speed of 300-350 rpm, a pressure of 50-70 atm ., heated for 30-50 seconds to a processing temperature of 160 ° C, the processed native gluten is transferred through the processing zone into the matrix and the resulting protein mass is pressed through the diameter of the matrix die openings - 3 mm, then the texture is cut pellets, and then cooling and drying at room temperature or in a dryer. As a result of this treatment, agglomeration of the particles of the feedstock into a continuous test mass of the macroporous structure and partial denaturation of the proteins of the feedstock, which, however, is accompanied by a slight change in the internal structure of the feed particles included in the agglomerate, are achieved. This is evidenced by the presented data on the change in the NSI index of the product, which varies from initial values of 50-80 units to values of 25-45 units after its processing, and the enzymatic activity of the urease enzyme, which varies slightly as a result of the processing regimes used in the invention. The proposed method is a unique process that is intermediate between the one used for the production of compacted granular products from a fat petal on an extruder expander and textured products from nonfat raw materials - highly porous, layered, imitating the structure of meat tissue products produced on twin-screw extruders. As is known, the PDI index of 18-20 units is characteristic of these products, and the urease activity is less than 0.01 units. For traditional classical extrusion of obtaining textured protein products in extruder screw devices or extruder-expanders, as you know, a prerequisite for the production of high-quality textured products is the presence of restrictive matrices in the end zone of the equipment, which prevent the free exit of the processed mass and ensure the creation of these end zones of these devices significant pressures and high shear deformation effects. It is these processing conditions that provide the product with a layered, lamellar finely porous structure.

Execution example.

For carrying out the research, Cargill native dry wheat gluten was selected with a protein content of 70% and carbohydrates 15%. the moisture content of gluten itself is 6.5%.

Testing of the technological modes of extrusion processing was carried out on a twin-screw extruder of the Werner und Pfleiderer brand.

The diameter of the die hole was 3 mm and remained unchanged. The cutoff voltage and the cutting work were determined on an Instron instrument.

During the extrusion processing of gluten with a moisture content of 40%, it was found that the diameter of the product remains equal to the diameter of the die (3 mm), and the product at the exit of the extruder has a light yellow color (beige color) and a friable structure. The pressure in the extruder changed with increasing temperature and auger rotational speed; these and other parameters are interrelated and have a significant effect on the final result.

Extrusion processing was carried out at: T = 160 ° C, screw rotation speed n = 350 rpm, P = 58 atm.

As a result of determining the chemical composition of the obtained texture, the following data were obtained

The chemical composition of the samples

70 ± 0.5 protein, 4.28 ± 0.5 fat, 6.52 ± 0.5 moisture, 4.2 ± 0.5 ash, 15 ± 0.5 carbohydrates

Essential Amino Acids

Lysine - 1.8 ± 0.02

Threonine - 2.6 ± 0.02

Leucine - 7.6 ± 0.02

Isoleucine - 4.6 ± 0.02

Valine - 4.7 ± 0.02

Tryptophan - 1.1 ± 0.02

Phenylalanine + tyrosine - 8.5 ± 0.02

Methionine + cystine - 3.8 ± 0.02

Histidrine - 2.3 ± 0.02

The total amount of NAC - 37 ± 0.02

According to the results of the application of the technical solution, it is clear that samples with textured gluten have better indicators than just native gluten, namely, the degree of hydration, BCC and LSS are an order of magnitude higher.

We use the resulting texturate to enrich meat products, with the percentage of introduction of the selected gluten texture to 8%.

The method of introduction into meat systems is in hydrated or dry form, followed by the addition of water for its hydration (1: 3,5) for uniform distribution of texture in the minced meat;

It is also possible to use gluten texture for the enrichment of minced meat semi-finished products and sausages as a substitute for raw meat.

In addition, it is possible to use for enrichment products intended for the nutrition of people with all forms of diabetes (a product with low dextrose and glycolytic equivalents).

Thus, approaches to enrichment of meat minced semi-finished products include: the choice of texture and the method of its introduction into meat products.

Considering all the factors, it is recommended to introduce gluten texturate into the product in a dry form, followed by the addition of the necessary amount of water for its hydration in the process of preparation of minced meat, or immediately in a hydrated form. In this case, the texturate is soaked in cold water, depending on moisture absorption and incubated for 10-15 minutes. Hydrated texturate has a loosened structure, which contributes to its better distribution in minced meat. Then, the hydrated sample is added to the meat mass in a mixer or cutter at the beginning of the mincing process to increase the surface area of the particles due to the violation of the integrity of the texture subunits. All this allows him to be evenly distributed throughout the meat system.

Thus, improving the quality of the target product, maintaining a high level of biological and nutritional value of raw materials, suppressing pathogenic microflora and obtaining a product with specified parameters and a high protein content in dough.

Table 1 Change in the structural and mechanical properties of extrusion products depending on the temperature and speed of rotation of the screw.

Temperature ° C Screw rotation speed, rpm Sample diameter, × 10 ^-3 m Explosive ratio Bulk weight, × 10 ^-3 kg / l Cutoff voltage, × 10 ⁵ N / m ² Cutting work, j 250 3.01 1.05 419 3.84 925,13 150 ± 0.15 ± 0.05 ± 7.33 ± 0.13 ± 25.15 300 3.23 1.15 376 3.65 873.00 ± 0.22 ± 0.07 ± 8.52 ± 0.06 ± 26.98 350 3.32 1.19 342 3.22 823.00 ± 0.24 ± 0.09 ± 9.47 ± 0.17 ± 23.02 250 3.11 1,11 402 3.78 921.68 155 ± 0.20 ± 0.08 ± 8.62 ± 0.13 ± 29.6 300 3,54 1.25 339 3,55 866.72 ± 0.23 ± 0.08 ± 7.31 ± 0.10 ± 25.36 350 3.86 1.34 326 3.20 817.33 ± 0.15 ± 0.06 ± 5.95 ± 0.18 ± 24.03 250 3.15 1.13 388 3.71 917.27 160 ± 0.26 ± 0.08 ± 9.74 ± 0.11 ± 28.63 300 3.65 1.29 331 3.49 856,46 ± 0.21 ± 0.07 ± 6.21 ± 0.12 ± 22.18 350 3.97 1.36 310 3.15 809.28 ± 25.00

± 0.11 ± 0.04 ± 5.63 ± 0.10

Claims (1)

 A method of manufacturing a modified food supplement based on wheat gluten for enrichment of meat products, characterized in that the native gluten is introduced into the processing zone located directly in the chamber of the twin-screw extruder, where it is moistened up to 35-45% by introducing water / water vapor into this chamber , and also subjected to continuous extrusion processing for 30-50 s at a screw speed of 350 rpm and a pressure of 50-70 atm, while heating for 30-50 s to a processing temperature of 160 ° C and with specific mechanical energy in the range of 380-410 kJ / kg, then the processed native gluten is transferred from the processing zone to the matrix and then the resulting protein mass is pressed through the rotating screws through the diameter of the die of the matrix - 3 mm, after which the outgoing tourniquet is cut into granules and then carry out their cooling and drying.